Iron Man Foam Completed Assembly Questions/Ideas

Hey I like this thread idea so I'll post.

Whilst I'm not quite at the stage of assembling parts, throughout my build I have continually been looking at how each part fits together.

My suggestion, and I will be using this method, is to use the sideclips and webbing like Stealth says in this tutorial TUTORIAL - "SUIT UP!" How to Connect Foam Armor Costume Parts - YouTube however I will be coupling this with velcro for added hold. So the webbing/clips will hold it in place structurally and the velcro should hold the additional parts down aesthetically.
 
Did anyone here make the abs in a way that actually allows for movement (specifically mark 3)? If so how did you do this? I was thinking of overlapping the pieces and using a wide elastic band to keep them coming back into place after stretching them. I was also going to do the same but without overlap for the spine and thigh cover pieces...
Any suggestions would be appreciated.
 
I originally had all the pieces of the abs (front, back, and sides) all done separately and had issues with pieces poking out where they shouldn't and the paint really got messed up where everything was rubbing. Recently I glassed each vertical section together using a couple of strips of fiberglass and am still working on how to connect them all. I ended up using a strip of aluminum to connect the back part to the cod and am toying with using alum strips to connect the sides to the back. The issue is having enough flex to put the abs on, and yet still have the pieces all come together and look good in the front...and to keep them up. have tried using elastic and it can be done, but hot gluing elastic directly to the fiberglass isn't very effective, it works better if you sew some really textured webbing to the parts of the elastic you want hot glued and glue down the webbing instead. Otherwise as the elastic stretches, the hot glue eventually releases and pieces start coming apart. I've also tried snaps and they work OK, but tend to pop apart where there is more pressure--maybe bigger snaps would work better. Here are some pics of what I've tried. The first 5 pics show how I did my elastic. The pics of me suited up shows how the elastic didn't really keep the pieces together very well...which meant pieces were not aligned and I had a hard time getting all the abs tucked neatly inside the chest/back. The last 4 show the three sections connected with strips of glass I ran down each edge to keep the 4 strips together, and show the aluminum piece I am trying out to keep the back of the abs connected to the cod. I found that if the abs were strapped to my harness, or to the back piece, they tended to fall down into the cod and make the cod pop apart (it is held together with mongo rare earth mags originally 8, but I added 4 more hoping there is now enough pull to keep it all together). I haven't yet connected the side abs to the back piece so that's still a WIP.
 

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