Iron Man Mark 39 WIP

[Shaunbrook7104]

Hey guys hope this grabs some interest. I've started a Mark 39 Gemini suit in paper pep files to challenge myself and I haven't seen anyone do a Mark 39 full suit yet (Maybe there is a reason for that). I've been doing small pep files for a while now and decided to go big or go home!!!

Its my first full scale build and I would like some help and advice so feel free to add comments for everyone to enjoy! It's going to be a slow build as I have a full time job and will only be doing it on my days off as after 12 hours of grafting I just want to go to bed haha!

I might be using different terminology and products as I'm from the UK.

Anyways here are a couple of pics to send this thread on its way

 

[Shaunbrook7104]

So I was busy on my day off and threw together the helmet. I went for a low poly pep here as I wanted to put the detailing in after I had made the rough shape of the helmet!

After cutting all the bits out I then had the daunting task of assembling it grrrrr. This is one of the reason I went for a low poly helmet

So I coated it in the basic fiber glass method then I would normally go and use fiber glass tissue to reinforce it but having seen so much success on the forum with the rondo method I gave that a whirl Needless to say I was rather impressed with my first rondo and the end result even after 1 coat. I used a 50/50 mix of body filler and resin, and as both of these used the same hardener I just mixed everything in a mixing jug and boom it worked!

So it dried in about 1/2 hour to 3/4 and I wasted no time in putting what little body filler i had left on the face plate and back of the head. I then went at it with the rough stuff to take away the excess BF and so that I could see the paper coming though to give me a reasonable surface to work off.

That's when I called it a day as it was to late for me to go to the shop for more body filler and goodies So I've attached loads of pic let me know what you think and tips are welcome.

 

[Shaunbrook7104]

More pics of my progress on here! Went out and bought a Bosch sander and it works really well. Its got a nice smooth finish on its work and doesn't sand your helmet away to nothing which is a added bonus

I penciled in the detail only roughly for reference purpose and I'm not rally happy I'll have to redo those but i wanted to keep an eye on the edges as I'm sanding and filling. I found a peace of aluminum checker plating in the workshop so i turned it into a useful clip board for my reference pics of the suit.

Let me know what you think guys???

And without further a due the pics

 

[George Firingos]

It looks great!! Would you use the Rondo method again

 

[streetsoul]

looking brilliant buddy keep it up i started doing this but i have it on the back burner at the min due to my mk 42 build i want to be the first person to build the mk 42 in paper fully

 

[Shaunbrook7104]

I would use the rondo method again yes! I'm going to apply a thicker coat later after I cut the face plate out. Cheers streersoul I intend on doing it all paper pep hopefully

 

[GhostMinion]

Good work so far!!! Keep it up!

You've inspired me to do some more polish down on my Gemini lid!!!

 

[Shaunbrook7104]

Nice work so far mate. How do you Intend to do some of the detailing? Like the cheek vent and the grooves around the eyes?

 

[GhostMinion]

Nice work so far mate. How do you Intend to do some of the detailing? Like the cheek vent and the grooves around the eyes?

Don't know yet....currently I'm pepping the Gemini helm by Syrus54, which has a lot of the detail. I'm guessing, however, that I'll carve the details into the bondo. I'm starting to think I will not motorize the faceplate either, and just cut a portion of the back out to get in and out.

Don't know for sure.....too many helmet projects going on at one time. Out of eight or nine helmets, that's the ONLY one I've got body filler on yet.

 

[Shaunbrook7104]

I did start syrus54's helmet but its a little bit to detailed. However I'm going to use the rest of his files for the build. I don't know about putting servos in but am definitely going to cut the face plate out!

I've stockpiled loads of reference pics for the armour but can't find any showing the back of the head of the movie armour and not the hot toys!

 

[halopepakura]

Fear not my friend, I have you covered
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View attachment 233258

 

[Shaunbrook7104]

Fear not my friend, I have you covered
View attachment 233257
View attachment 233258

I haven't seen those pics yet. I've googled the hell out of the Mark 39 but get the same ones over and over grrrrrr.

I've been scratching my brain as how to get the detailed hexagon patterns on the armor. I was going to try cutting an A3 sheet of hexagons on the Cameo then make a box to poor a super thin layer of RTV silicone in there. and make my own silicone film almost. Or just stick Carbon Vinyl on it and make do

On my last night shift tonight so more updates to follow in the next few days. Hopefully going to resin the chest and shoulders

 

[Shaunbrook7104]

Update time!

Haven't been too well so not as much done as I hoped for really Needless to say i did alot more sanding and smoothing and am happy with the overall shape. I went over the helmet a few time to find the center line which I penciled on, I then drew on all the detail lines after about 1 hours measuring down to the mm! I masked it all up then hacked at it with the Dremel I used the speedclic shaft from Dremel and the diamond cutting disc to go with it. I think it did a really nice job and you don't get all those little wheels breaking and almost blinding you. Recommended attachment with a thumbs up.

Anyway here are the after pics of the helmet as I didn't get any while I was doing the prep work as I was in the ZONE!



Did a bit more pep work to so I have both forearms, biceps and started the boots too yayyyy

 

[Madosheet]

this is looking awesome! Greatwork Shaunbrook7104!
Only had enough time to quickly skim through the thread just, but I've subscribed so I can come back later and read it properly; especially more so that you're also from the UK and have successfully done the rondo method that I've been planning to try!

Keep up the good work, and all the great pics! Inspires and also has lots of tips for a lot of us !

 

[Shaunbrook7104]

Thanks for the support mate. I struggled for ages with fibreglass reinforcement and was so time consuming! I got my body filler and fibreglass resin from Halford's and noticed they used the same hardeners so robbed a plastic measuring jug from the misses (sshhhhh she still doesn't know haha) and mixed a 50/50 ratio to start. Now I've cut the face off I'm going to place a rim on the rest of the helmet and face to apply a thicker coat of rondo( less resin) I'll post more pics before I do this time!

 

[Shaunbrook7104]

Bigger update today!

I applied some strips of card to the helmet and face plate so when I add another layer of rondo it won't drip everywhere and have a uni-formal edge to work to.

Some pics of the helmet work.


I also started working on the forearm and shoulder today. I put some kebab sticks on the shoulder to hold it in too place whilst I epoxed it as the .PDO
didn't have supports. I then mixed a batch of bondo and tipper it on. No finesse was used here at all hence the blue drip sheet it dried a bit quicker this time as I put a little more hardener in the mix. It got a little warmer this time to but I could still hold on to the peaces whilst rotating them.

Some pics I took as I went




And whilst the misses wasn't paying attention I vanished into the man cave and put some bonbo on the new suit peaces hehehe.



And last but not least safety first people always wear a respirator

 

[IronGemenis]

Wowowowow, very good work guy very good, i have work in my mark 39 gemini by Syrus 54, see your post for other files.

 

[GhostMinion]

Hey Shaunbrook, the build is looking very nice! Wanted to show you the lid I just finished:






What do you think?

 

[John Adrian]

Will subscribe to this thread interesting costume

 

[Shaunbrook7104]

Looking good mate! Is that syrus54's helm I assume? Back in work for 3 days now so no major updates just sit and cut some peps out for the back! I really cant wait to start the chest but want to wait till I've got the back done then I can rondo them all together then split them. Hopefully will hold their shape better and not warp as much. You planning on doing the whole suit?