Iron Man - Mark III (first project, foam build part almost done)

ThatPhoenixGuy

Active Member
PLEASE NOTE:

I'm aware that the files I used to build the first helmet were out of date. I've started to use foam in the meantime anyway. You can see currents results by scrolling down a bit. Things have changed since I've started this thread. I just keep those old pictures here so that everyone can see my progress in hopefully getting better with this kind of work. Maybe someone will feel inspired to start a build himself :)

And if there's someone out there who's interested in starting his first foam build: I hightly recommend this thread here: http://www.therpf.com/f24/foam-speed-building-filesntricks-multi-hero-cowl-148889/

You'll find some good files and advices over there. Most of the models have a lack detail but are pretty easy and fast to build and I think those files are just the ones to start with :)

I'm myself are using the MKIII files, originally modeled by DancinFool and altered and converted to Foam by JFCustoms

Current State:

Foam building in process
  • Right arm finished (including shoulders)
  • Left arm finished (including shoulders)
  • Right leg finished
  • Left leg finished
  • Torso finished (including flaps and spine)
  • Abs finished
  • Cod finished
  • Boots finished
  • Neck finished

Material:

I'm currently using PE floor mats (8mm thick) which you can find here:

Schutzmatte DF920 DOMYOS - Fitness_Cardio-Training Fitness (DOMYOS) - Decathlon...

Most foam tutorials tell you to lay the templates on your foam and then draw around them so you'll know where to cut. But that can be pretty inaccurate in my eyes. I just pin the templates to the foam and then cut directly along the templates :)

Tools:

I'm using two different cutter knifes with snap-off-blades (a small and a big one). You will find yourself needing a lot of blades. I recommend to sharp your blade like once a day. They'll last a lot longer. And you'll need a heat gun and some hot glue and maybe a good pair of big scissors (depending on what foam you're using).

And for getting clean circles and curves you can try out circles cutters. They're meant to be used for cutting paper but when you start with scrathing the foam and work your way deeper and deeper into it with every spin you can get pretty clean results. At least with the foam I'm using :)

circle1.jpg
circle2.jpg



----------------------------------------

Hey everyone,

I'm totally new at therpf.com (although I've been reading and watching as a guest for a few days now).

I've decided to go for the Iron Man Mark III. I'm using pepakura files from callmemilo and Belakor as a basis.

This is my first replica project what so ever so I'm still in a state of testing, checking and evaluating.

Two days ago I've startet a rough and quick version of the helmet just to make sure the whole project was doable for an amateur like myself.

mark1_1.jpg



mark1_2.jpg


As I said: it really was just a rush through.

Today I started work on the "final" version that is going to be covered with some papier mâché. If that's going to work out I'm thinking of using glass fibre for the real thing.

mark2_face_1.jpg


So. This is me. Just remember: I'm an amateur :) Looking forward for some interesting discussions and advices of any kind :)
 
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Re: Iron Man - Mark III (first project)

You might want to go with an HD helmet pep file

yeah go with dancin fools
 
Re: Iron Man - Mark III (first project)

holy mother...thanks a lot, stealth and royal dump!!!!

You've saved me from a lot of swearin' as it seems^^
 
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Re: Iron Man - Mark III (first project)

yeah, we're ol' timers with this stuff. np

good luck, have fun building man.
 
Re: Iron Man - Mark III (first project, WIP)

After having restarted the thing in advance of using dancing_fool's awesome pepakura files (found: here) I'm mostly done with he paper version of the helmet.

Still have to tape some edges properly but for this being my first project what so ever I'm pretty happy with the outcome...... despite the fact of seeing all the super clean builds posted across the message board.

I put everything I got in that helmet but without any professional tools, I still have to cut and tape everything together by hand. So please don't be hard on me if it's not as good as most other versions.

Next steps are covering the damn thing with 2 layers of papier mâché to add a bit more stability and losing some of the edges before covering it with some fibre glass.

mark3_1.jpg
 
Re: Iron Man - Mark III (first project, WIP)

Nice job so far, good clean pep work, those files were great for their time but as other have said very outdated and if you gonna continue with Dancin_fools files you should also go with a more accurate helmet to match the rest of the pep. here is a link to the best pep helmet file IMO the Sharkmark VI, I just finished this helmet myself
Sharkmark VI-IronMan-Helmet-UnfoldedbyDubean33.pdf - 4shared.com - document sharing - download
 
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Re: Iron Man - Mark III (first project, WIP)

And I really thought I nailed this time :D Thanks for the update, man :)

After looking at Sharkmark's pep files there's one question in my mind. It looks like I'll have to cut out the eyes myself after finishing the helmet (including papier mâché and fibre glass layers). Am I right?

And thanks a lot for the help. It's really hard to find the most accurate and updated pep files, even after doing a fair amount of research.
 
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Re: Iron Man - Mark III (first project, WIP)

And I really thought I nailed this time :D Thanks for the update, man :)

After looking at Sharkmark's pep files there's one question in my mind. It looks like I'll have to cut out the eyes myself after finishing the helmet (including papier mâché and fibre glass layers). Am I right?

And thanks a lot for the help. It's really hard to find the most accurate and updated pep files, even after doing a fair amount of research.

Dont even bother pepping the parts that fit inside the eyes as you would only cut them out anyways, you dont need them save yourself that step:)
 
Re: Iron Man - Mark III (first project, WIP)

So things have changed. After spending weeks and months on research and after seeing so many great foam builds here lately I've decided to go for foam myself. So I did another couple of weeks of research for the right material and yesterday I finally started working on the first parts.

I know that this is going to be pretty boring but I've started with the handplates. I just found them to be the easiest parts to start with. They've come out far from being perfect but I'm still happy. The only thing that bothers me are the missing sharp edges but I'm sure I'll figure it out soon. I thought about using duct tape to hold the edges together from the outside and then hot glue the ***** out of the parts from the inside.

I also did a little tweek on the way I cut out the parts. I've always read about using the printed templates to mark them on the foam. But I've figured that I'll be getting much cleaner cuts if I'll just pin the templates to the foam and cut directly along the templates. It worked out pretty good and detailed as I think.

As I've said before: far from being perfect but I'm happy :)

handplate1.jpg



handplate2.jpg



handplate3.jpg
 
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Re: Iron Man - Mark III (first project, WIP)

So I've done a bit more work in the past two days. My cuts and glueing edges are still for from complete and I'm still learning how to heat up the foam to get the right curves into it but I'm slowly getting into it.

So here are my shoulders. I'm still thinking about a better method to build those small dongles.

shoulders1.jpg



And here is my first complete forearm. I'm pretty happy with it despite the fact that I didnt' really managed to make a real tube out of the inner piece. You can actually see the bad glueing edge there on the left end. But still. I think it's pretty decend for my first foam build. But I'm already plannung to rebuild most of the parts as I'm getting better foam building skills^^

forearm1.jpg
 
Re: Iron Man - Mark III (first project, WIP)

Looking good! You're really making progress on this, and fast.
 
Re: Iron Man - Mark III (first project, WIP)

So this has been another very productive day. I built an elbow and both biceps and again: I'm getting more comfortable working with foam. More glueing edges tend to come out better than a few days ago and I'm really starting to understand how to heat and bend the pieces to get them into shape. But again: far from being perfect but for now I'll live with it. It just one of those learning by doing things what basically means that I'll have to just build more and more pieces to become better^^

So this is what I have now. Thanks to my sister for standing in as a model. Please remember that the suit is not scaled for her but for me, so the pieces are to big for her ;) And the helmet is an old pep helmet I still have. Just thought it would be nice to complete the impression of the pieces. I will build another out of foam :)

armRight1.jpg



armRight2.jpg
 
Re: Iron Man - Mark III (first project, WIP)

how are you planning to seal your foam? plasti dip method, bondo/resin mix or smooth-cast method? because speaking as some1 with their own foam suit it gets very hard to hide valley seams with out some kind of filler material
 
Re: Iron Man - Mark III (first project, WIP)

Smooth-Cast isn't really an option over here in Germany 'cause you can't really buy it anywhere. I was thinking about putting some layers of PVC on there before finishing it with resin and sanding it down. I'm not quite sure yet what to do about the seems.
 
Re: Iron Man - Mark III (first project, WIP)

Well, we all just hope that such a thing may be cheap and superior at the same time. Goodluck guyz... It'll be a great success for sure.
 
Re: Iron Man - Mark III (first project, WIP)

I'm aware that this thing won't be cheap. I think anyone who does a bit of research realizes that pretty quick^^

I'll keep you guys updated which methods I'm gonna try :)
 
Re: Iron Man - Mark III (first project, WIP)

Another day, another piece is done. I'm happy to say that both arms are done right now :)

arms1.jpg



arms2.jpg



And what makes me even happier: my glueing edges are really looking better. I think those are pretty clean :)

arms3.jpg
 
Re: Iron Man - Mark III (first project, WIP)

What can I say? I've been busy today making the right thigh. Just another small piece but this time I'm really happy with the outcome. The edges and curves look so much better than they did at my first pieces :)

The only thing I don't like is the dongle and I'm thinking about having those 3D printed together with the shoulder dongles :)

thighRight1.jpg


thighRight2.jpg
 
Re: Iron Man - Mark III (first project, WIP)

yeah...don't forget to pull the needles out before you try it on ^^
 
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