Iron Man Mark 7 Foam Build

[Gaz]

Hi everyone,

As you can see, I'm brand new here and I'm also brand new to the very idea of costume construction.

However, I am attending a ComicCon event in July this year, and the only cosplay I am really passionate about is Iron Man. Through some random youtube surfing I stumbled across a few tutorials by Stealth, which lead me here. Though I'm daunted by the scale of the project, I'm determined to invest whatever time, effort and money is needed (within reason, obviously!)

I've already started construction on a "new style" Arc Reactor to complement the Mark VII costume, initially based around Stealth's tutorials, and now I'm improvising (now I've got a little confidence). Once I'm comfortable with the AR build, then I'll start on the full armour, probably within the next few weeks.

I've already decided that I'm going to go down the avenue of using modified foam Pepakura templates instead of card. I'm a Mac user, so I'm in the process of getting hold of a copy of Windows to run the viewer software. I've got the files from another thread, but am yet to have a good look at them and understand them. Will the files I have be appropriately scaled (to a 6 foot average build male) as default, or will I have to do a couple of tests to work out the sizing?

After reading around the various threads on here for the past few nights, I've sourced a supplier of Plastazote LD45 in the UK. Most people seem to be using 6mm EVA foam, but some use 10mm. Before I order one or the other, Ignoring the cost difference, what is the difference in the finished product, or difficulty?

My method then would be to seal the foam with 5 coats of diluted PVA, followed by Plasti Dip. Do I need PVA and Plasti Dip, or is it either/or, as I couldn't quite work this out? Also, would I be better off with the spray can Plasti Dip or 'pot and brush' style?

That's all my questions for now. I'll update you and post some pics as and when. Thanks.

 

[Cooper648]

Hello there, I am glad to see that you are so interested in building an Ironman suit like myself! I am working on a mark 39 space suit at the moment as well as a mark 42 helmet. Lets start from the top here. When using EVA foam, I prefer to use the 6 mm type. It comes in a role that lasts for a while, it is also very easy to manipulate and very fool-proof. I have found that the 10mm, although very sturdy, can be very difficult to form and build with at times, especially if you are building a helmet. Most foam pep files for full suits of armor are usually always scaled to measure a 6 foot person unless directly specified. If you plan on hardening you suit with fiberglass resin, you must use PVA glue, but if you want a flexible suit, you can just use plastidip as it keep paint from chipping when bent. No need to coat a suit with PVA and Plastidip if you just want a flexible suit. To harden a suit I use PVA glue and do 3 coats of the stuff on my foam builds to seal it and cover up any imperfections like bubbles in the foam or scratches to protect it. I then coat it with a few layers of fiberglass resin to harden it up. After its hardened I just sand and perfect with bondo spotting putty. I hope this helps, let me know if you have any questions or concerns!

 

[Gaz]

Thanks for the response Cooper.
I think you've settled my mind into purchasing the 6mm, it was only one person who suggested 10mm and that kinda threw me.
I confess I'm a little nervous at the idea of resins and fibreglass as I've got limited space at home, and Plastic Dip looked comparably easy with somewhat similar results. Likewise, XRobot's method of plastic coating panels looked very attractive, but again I just haven't the space to work that kind of setup.
As I want a hard structure, does that mean I will need to use PVA to harden, and also Plasti Dip for the required coating?

 

[Cooper648]

You only need to use PVA glue to coat your foam build before hardening to protect it. Plastidip is only used for soft flexible build. Hope this helps!