Inexpensive 5 days built ►Foam Iron Man Mk IV◄

Discussion in 'Marvel Costumes and Props' started by JFcustom, May 14, 2012.

  1. JFcustom

    JFcustom Sr Member

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    Hello users,
    my 3yo daughter's school carnival's day was aproaching, and it would happend just the day of my birthday. Parents who accompanied where invited to disguise too, so I decided to release myself, making an old dream come true.

    So, I surreptitiously picked up robo3687 iron man mark 4 foam pepakura templates (robo3687 you're my personal Jarvis), took an half-day for shoping, whole day for revising and modifying pep files (I prefer taping multiple sheets together to have larger pieces of foam rather than cuting and regluing many small foam parts, this way it seems I save a lot of time) and began cuting and gluing (my fingers and) yellow and pink 6.5mm PE foam... With the instant agreement of the original modeler : here are Robo3687's files, foam unfold JFcustom .

    Glue, brand new sharp cutter :

    [​IMG]


    Seven pink and one yellow :

    [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]


    Two coats of Sikafill TM, and first coat of paint :

    [​IMG] [​IMG] [​IMG] [​IMG]

    Second coat of paint, more accurate, and let's try it out :

    [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]






    [​IMG] [​IMG]



    [​IMG] [​IMG]



    Next I'll show you pics and tricks about the damned-clever tips and tricks and cheapy materials I used to connect the parts, and to buid in 5mn an amazing 2 bucks lighted ARK reactor ;p


    __________________



    And after that, my next realisation and work on unfolding and building this foam-pep Guyver will be the object of a new post...
    spoiler1
    spoiler2
    :love
     
    Last edited: May 16, 2013
    BGefrich likes this.
  2. StarksWarehouse

    StarksWarehouse Active Member

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    I have to say, for a time limited build this looks really nice! Can't wait to get on my computer to see the pics in full size.

    Sent from my BlackBerry 8900 using Tapatalk
     
  3. astromechr4p17

    astromechr4p17 New Member

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    Re: 6.5mm Foam Iron Man Mk IV, french labeled.

    Nice work!!
     
  4. JFcustom

    JFcustom Sr Member

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    Re: 6.5mm Foam Iron Man Mk IV, french labeled.

    my cheapest operational ARK reactor for moneyless


    - you need -


    An Evian bottle bottom, 2 inchs height :

    [​IMG] [​IMG]


    One of this kind of pics, of your choice, printed on the thiner paper you can find, cut along the dotted, and then oiled for a better transparency :

    [​IMG]

    [​IMG] [​IMG] [​IMG] [​IMG]

    [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]


    A 80mm white round reflector, as you can find at the front of caravans or trailers (keep only the transparent part, of course, but better is to specify it however) :

    [​IMG]


    A led(s) push-spot

    [​IMG] [​IMG] [​IMG]


    and a roll of tape

    [​IMG]




    - HOW TO -

    Fill your bottle's bottom with

    1. pic of the ARK, printed side turned down,
    2. reflector, rugged side down, slicky side up in front of the leds,
    3. led spot, lights turned to the reflector
    4. cross tape your bottom's bottle to keep all inside in place.
    5. Insert the thing in your chest, it fits perfectly, and holds alone.

    [​IMG]

    Push, it works.
    Price : 2$
     
    Last edited: Apr 5, 2013
  5. madrick

    madrick Active Member

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    Re: 6.5mm Foam Iron Man Mk IV, french labeled.

    that arc reactor is genius-ly simple and effective!
     
  6. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive Foam Iron Man Mk IV, french labeled.

    Joining articulated and some sealed parts :

    I used to work as graphist in a publicity agency, and we had always somewhere in the office a couple of useless and sun-faded color charts.

    [​IMG]

    And ?

    And I kept thinking that the potential of these pretty little plastic juncture clips were heavyly underexploited.

    [​IMG]

    So I ordered a pack of 100 pieces, as it almost doesn't costs anything.

    [​IMG] [​IMG] [​IMG] [​IMG]


    You can find some here or here or here or here... of various shape, color, diameter and thickness.

    [​IMG] [​IMG] [​IMG] [​IMG]



    And I promise you some discret and incredibly easy attaching for mobile parts (knees elbow toes...) as well as sealed parts such top chest, flaps, handplates, spin and so on... depending of the pressure when cliping.
     
    Last edited: May 15, 2012
    BGefrich likes this.
  7. crabra comander

    crabra comander Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    You are some type of penny pinching god! Great work, good parts breakdown.
     
  8. CapKaos

    CapKaos Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    You are an amazing human being!! I've been running myself ragged trying to figure out an inexpensive way to fashion an arc reactor that would look good. And you did it! I'm going to be taking a lot of inspiration from this thread. Three quick questions, what paint did you use, where did you get the foam, and how much was it? Again, amazing job!!!=)
     
  9. theblueraja

    theblueraja New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    MaGuyver has got nothing on you!
    Excellent build! :)
     
  10. TKSteve

    TKSteve Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    You gotta be kidding me! Nice work.
     
  11. TheNickFox

    TheNickFox Sr Member RPF PREMIUM MEMBER

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Fast build and great work.

    I'd hate to see what you could do with more time and money...You'd probably end up inventing a fully functioning, flying Iron Man suit. :lol

    Keep up the great work.

    -Nick
     
  12. outofcontrolreb

    outofcontrolreb Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    You have some great ideas and I like that there cheap. Thanks, great work
     
  13. Nobody

    Nobody Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Great work!!!!! Also, some great tips, thanks.
     
  14. Egon

    Egon Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    5 days? That is unbelievable.
     
  15. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV


    I thank you all for your compliments, you know I just followed your technics and tutorials and I keep in mind I would still be in underwears without theRPF. So I want to congratulate you.

    Well, what paint did I use... I picked four cheap 10$ red Technoral acrylic sprays, color chart RAL3004, and one common 6$ golden spray that I half used for chistmas decorations.

    [​IMG]

    I got the foam at Decathlon, a discount sport articles store chain supllier of Oxylane products, sold as fitness mats. A kind of 140x50cm polyethylene carpet, 30 Kg/m3, 6,5mm thickness.

    7 pink ones >>here<<

    and a yellow one >>here<<

    [​IMG]

    2.95EUR, meens about 3.75$ each.


    Note that these paints do not hold on foam, and once dry crack on a single bend. Add that this foam is not completely slick. I had to apply in the hurry a couple of coats of Sikafill, an industrial flexible waterproof coating to seal roofs, to harden foam and make it smoother, fill gaps and hide few trivial bonding failures. And moreover, paint adhere on perfectly.

    I could find less expensive than Sikafill, it would have given exactly the same result, but I already had, deep in my workshop, an old opened bucket of it...
    You can count on 500ml for three heavy external coats, ie 6 more $.

    On second thoughts, in the end it's quickly not so cheap...

    ... and 5 days, and nights, was just enough for my wife not to blow a fuse...
    I must say I slept better the following week.
     
    Last edited: May 15, 2012
  16. omel

    omel Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    bravo sir! bravo!!!
     
  17. CapKaos

    CapKaos Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Ah, I see. Another question (if you don't mind of course)? You said in your first post that you prefer to tape mats together to make bigger pieces instead of smaller ones. What did you mean by that? And thanks for the advice! I'll definitely keep it all in mind once my build begins.=)
     
    Last edited: May 15, 2012
  18. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Well, it's a good question. In fact I wondered why nobody asked it before.
    I do not exactly tape mats, my english must be rusted...

    So, here we go.
    On all pep file I found, it's always the same : objects are cutted in a profusion of smaller parts that always fit on a paper page. A4 or Letter. And of course it is, because pepakura is originaly designed to realise objects whithin paper itself as soon as a sheet comes out of the printer. You can't print a larger piece than a sheet of paper.

    But,
    I build with foam, not with paper. Paper is only used as a mask for cutting foam, because sadely my 1.40m mats can't be insered in my printer. I know, I tryed.


    Here's the hint, illustrated :

    an unrefined biceps : [​IMG]
    a JFcustomized biceps : [​IMG]


    an unrefined shin : [​IMG]
    a JFcustomized shin : [​IMG]




    an unrefined thigh : [​IMG]
    a JFcustomized thigh : [​IMG]

    and so on...



    1. print your sheets
    2. tape your sheets
    3. cut your paper masks
    4. cut your foam from the masks
    5. you get less and bigger foam parts, you save gluing time, and less junctions means nicer curves an inproved "anti-aliasing".
     
    Last edited: May 16, 2012
    ssSerendipityss likes this.
  19. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    As you could have noticed, an other trick is to keep some of the small rush parts of the original paper pep files, in order to enlarge some foam pieces to be sure to have enough overlap surface to glue parts together, while foam thickness keeps compensate the deleted part in the first pic below :

    Before : [​IMG]



    After : [​IMG]



    And this way for marking edges (shown from under) : [​IMG]
     
    Last edited: May 16, 2012
  20. StarksWarehouse

    StarksWarehouse Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    simple yet awesome tips there! why do i always go the long way around when the easy things are staring me straight in the face haha!
     
  21. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Aaah this old dear clumsy Angus, I taught him all he knows... :behave
     
  22. CapKaos

    CapKaos Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Wow, this is amazing! I otally agree with StarksWarehouse, I didn't realize how simple it could be with bigger foam pieces. Now, final question (I swear it's the last one!): Would you be willing to share your edited pep files? I'm not exactly a pepakura expert and though I have the program and the original foam files, I don't really know what I'm doing.
     
  23. JFcustom

    JFcustom Sr Member

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  24. theblueraja

    theblueraja New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Excellent! I've just been looking to play around with modifying some of the available pep files to foam or trawl other threads for them, but here they are in a convenient pack! :)
     
  25. CapKaos

    CapKaos Well-Known Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Thank you thank you thank you!! I'll definitely be using these to their fullest.=)
     
  26. firefly827347

    firefly827347 Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Nice work! Amazing what can be done on a budget :)
     
  27. CDub

    CDub New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Really great stuff considering budget and time constraint!
     
  28. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    I would soon have a little time to prepare a more operational files package. The one above is really much rough and outdated.
    Be patient.
    I'll be back...
     
  29. Bradester

    Bradester Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Hurry, Please! :)
     
  30. dkaniel

    dkaniel Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Are the files sized to your height and weight? If so what dimensions did you use so those of us not the same size can adjust the files as needed...thank you.
     
  31. dtstroud06

    dtstroud06 New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Dude this is awesome...I'm gonna start one soon. Great work bro
     
  32. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    dkaniel -> I did not rescale robo3687's original files. I'm 5'10" and it fits me well.
     
    Last edited: May 16, 2012
  33. jamiemcshan

    jamiemcshan Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Ok, I think I just figured out what my son is going to be for Halloween this year!

    Awesome work! Can't wait for your "good" files. I guess it's not hard to scale these down? I have never done Peparkura.

    Jamie
     
  34. Mrkipling

    Mrkipling New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Stunning work :)
     
  35. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    [​IMG][​IMG][​IMG] Here's an >>> instant workable release <<< [​IMG][​IMG][​IMG]

    for those who want to try right now if they can be done before monday morning...
     
    Last edited: May 17, 2012
  36. Xenuprime

    Xenuprime Member

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    Your thread has inspired me to try a pep build after my current prop is done, thank you!
     
  37. Davence

    Davence Guest

    Re: Inexpensive Foam Iron Man Mk IV, french labeled.

    First amazing costume on a budget there! second arr those "plastic juncture clips" avaiable in america at all?
     
  38. jjones

    jjones Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    [​IMG]

    Just wanted to post this, got bored on my lunch break and used you idea for an arc reactor. Just happen to have all the necessary materials laying around.
     
    Thoramyre likes this.
  39. Bradester

    Bradester Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Let me be the first to say THANK YOU for the files and your time putting them together!
     
    Last edited: May 17, 2012
  40. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Hey guys ! look at that ! A part of me has crossed the oceans through the web to reborn in Memphis ! I'm not alone anymore, now I know I can go peacefull... :love

    Thanks to you, for what you will do with.
     
    Last edited: May 17, 2012
  41. Bradester

    Bradester Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Hi again! HUGE favor to ask you or someone. It is possible to get your Pep files converted to PDFs Letter size? I have access to a Mac printer and a 3 day weekend!
     
  42. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    [​IMG][​IMG]
    Have a nice week-end.
     
    Last edited: May 18, 2012
  43. Bradester

    Bradester Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    You are about the most amazing person ever!
     
  44. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Looks better than mine. I hate you.
    If ever you were bored again, why not trying to find the right stuff to make palm's ones :thumbsup
    I found smaller transparent bottles, but they are square-shaped...:angry
     
  45. Bradester

    Bradester Active Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    I'm going to make my arc reactor from this one, but print the graphic onto a plastic transparency sheet instead of paper so the color comes thru. I think it'll work great, but won't be able to do it until Monday.
     
  46. haldir

    haldir New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    i beg your pardon but i can say to my french neighbor :

    C est juste parfait !! quelle source d inspiration, vraiment chapeau !(y)thumbsup

    et en plus un petit PM par la dessus!!



    Sorry for this french interlude...:lol
     
  47. Nattosan71

    Nattosan71 New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    I am new to this forum and replica prop making in general. Your posts and resources have inspired me to start my own build. Thanks for sharing and getting me started into such a great hobby. Good luck with your future projects.
     
  48. JFcustom

    JFcustom Sr Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Hey, haha, come and have a look at what I found both in garbage and in my attic :

    [​IMG] --->> [​IMG] --->> [​IMG]


    two small round AND transparent plastic bottles, and many supernumerary blue LEDs from my old DIY plexi PC case.

    [​IMG] [​IMG]


    These LEDs used to dazzle and made almost blind, and it perfectly matches because for once it's exactly what I'll ask them.


    [​IMG] [​IMG]


    I've got a whole weekend to dig my mind and cogitate on a cheap ans simple 'howto'...
    After all, wasn't Tony Stark able to build this in a cave...with a box of scraps ?
     
    Last edited: May 19, 2012
  49. MattH101

    MattH101 New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Awesome work JF!! Very inspirational foam build on a budget! Thank you for sharing your work and files. Time to get started on my build while using this thread for resources!
     
  50. IronMan9312

    IronMan9312 New Member

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    Re: Inexpensive 5 days built Foam Iron Man Mk IV

    Great build and thanks for the tips! :)
     

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