Iron Man Mark VI Foam Suit - My first build thread! Completed Pics & Further Progress

[keko]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

awsome yust I dont like the helmet ...

 

[xzmbi3]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

I like your thighs. mine came out terribly but it became bearable after i painted them. my mark vi took 3 months to complete. i like your progress. especially your bottle cap repulsors

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

The more I see of this build the more I am in awe of your skill.

thanks man!

Sorry to hear you didn't make it in time for the Halloween party weekend. :-( since Halloween fell in the middle of the week, maybe there will be some parties around you this weekend?? If not, you could always dress up as iron man for thanksgiving!! Lol why not?!?!
You have done a remarkable job. Better than anyone could have guessed, especially with your time restraints! Be proud of you suit. Remember, the Iron Man 3 premiere is in a few short months! =D

I should be able to still make it to the big halloween costume party at the casino in my area. $2500 first prize, $1500 second, and $1000 third. I think I may have a slight chance . As for my helmet, bad news on that front. It's still sitting in Customs in Memphis and they said its possible depending on the item it could get released today or 30-45 days later :cry. Looks like I will be pulling all nighters to rebuild a good one out of foam since my first one was terrible compared to the rest of the build. It's amazing how much better things look when you get the hang of it lol

I like your thighs. mine came out terribly but it became bearable after i painted them. my mark vi took 3 months to complete. i like your progress. especially your bottle cap repulsors

thanks! Bottle cap repulsors are quite durable too

 

[Shakeitdavey]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

The suit is looking fantastic!
I think it was mentioned before that it may be best to re-do the helmet.
Alot of people start the helmet first then do the rest of the suit. By the time they've finished the suit they are alot more knowledgeable in the process of the whole foam/bending/gluing procedure.
With that in mind, you obviously have the skill so I would say re-do the helmet using the heating/bending method and you could have yourself an Epic foam suit.

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

The suit is looking fantastic!
I think it was mentioned before that it may be best to re-do the helmet.
Alot of people start the helmet first then do the rest of the suit. By the time they've finished the suit they are alot more knowledgeable in the process of the whole foam/bending/gluing procedure.
With that in mind, you obviously have the skill so I would say re-do the helmet using the heating/bending method and you could have yourself an Epic foam suit.

thanks dude! I am going to try to remake the if I can.. still short on time as it is :unsure.



Ok so I have begun priming and painting the suit. Got first coats of paint on all pieces, and second coat on a few. I do a have question about the paint that has me worried. If you look at my close up of the boot (has 2 coats red already, no clear yet), you can see that the paint is glossy in some areas and dull in others. What gives? Wil the clear coat fix this? why is it doing this? do I need a third coat of red on them? help anyone?

Ant

 

[iMan]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

Nice work man! Can't wait to see the suited up photos.

Any tips for the legs? I need to start building mine here shortly

 

[Shakeitdavey]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

How long have you left the coats of paint to dry? I'm guessing it hasn't evenly dried which may be the reason for the patches?
Also, can i ask which foam did you use and where from?
Again, great work mate

 

[omarbou1]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

pores ? more paint !!!!
or primer filler

 

[demonwolfe]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

So I may sound stupid here but I haven't seen this technique for the repulsor, but this is pretty genius. If it's alright with you I may use this for my eventual build.

 

[Helagak]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

Ant the problem with the paint is that it is too humid where you are painting. I ran into the same issue when I painted on hot and humid days. I haven't really found a good solution other than waiting on better days to paint but I'm guessing that isnt an option for you.... You could try more, lighter coats but then you are still dealing with more time. I would just tell you not to worry about it and pound this thing out. Trust me, most people won't see all the imperfections that we see as we agonize over our builds. Keep up the good work. Good luck on the costume contest!

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

Nice work man! Can't wait to see the suited up photos.

Any tips for the legs? I need to start building mine here shortly

Thanks man. best thing I can tell you is to do both legs together, one small small section at a time. Glue two or three pieces on one, then repeat on the other. That way when you have to cut the angles for some of the pieces you remember right away exactly how you cut and glued them. thats how I did mine

How long have you left the coats of paint to dry? I'm guessing it hasn't evenly dried which may be the reason for the patches?
Also, can i ask which foam did you use and where from?
Again, great work mate

Well the boots were the first test. We left it on to dry overnight and the first coat looked great.

pores ? more paint !!!!
or primer filler

We are going to try more paint tomorrow, and the primer we used was "Rustoleum primer sealer"

So I may sound stupid here but I haven't seen this technique for the repulsor, but this is pretty genius. If it's alright with you I may use this for my eventual build.

Absolutely. It makes me feel great to know I contributed something somewhere lol.

Ant the problem with the paint is that it is too humid where you are painting. I ran into the same issue when I painted on hot and humid days. I haven't really found a good solution other than waiting on better days to paint but I'm guessing that isnt an option for you.... You could try more, lighter coats but then you are still dealing with more time. I would just tell you not to worry about it and pound this thing out. Trust me, most people won't see all the imperfections that we see as we agonize over our builds. Keep up the good work. Good luck on the costume contest!

could be. Its been pretty dry the last couple days though. I am definitely gonna try another coat on them. the first coat looked great and it was a windy day so I may actually put a floor fan on low to keep the air around it moving..

Ant

 

[FerrariF430]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

...
Ok so I have begun priming and painting the suit. Got first coats of paint on all pieces, and second coat on a few. I do a have question about the paint that has me worried. If you look at my close up of the boot (has 2 coats red already, no clear yet), you can see that the paint is glossy in some areas and dull in others. What gives? Wil the clear coat fix this? why is it doing this? do I need a third coat of red on them? help anyone?

You have a few painting issues and like pep'ing it takes many attempts to get the process for painting foam, in your environment where it will come out great.

0. Take an extra 30 minutes and get a large spare piece of foam, divide it into like 6x horizontal stripes using a sharpie. At one end write what the test area is for. i.e.
I. PVA, primer, top, PVA
II. PVA, primer, top no clear
III. PVA, primer, top, enamel clear
...etc, etc. Then you will find yourself referencing this test piece many times. You will discover many things. For example the best looking one is not the best choice for parts the flex a lot, but a slightly less shiny part that does not crack is superior for the application.
1. Seal the heck out of the foam. I use a real PVA from Amazon : Helmar Craft and Hobby PVA Glue, 8.45 Fluid Ounce. I first cut it 50/50 with water, and toward the final coats barely cut it. I seal until it looks like its a solid epoxy like surface. I have also used Modpodge successfully in the glue like and spray containers.
2. Primer lightly but completely
3. On a high visibility part (i.e. helmet) you might want to lightly sand at this step with 1500 or 2000 grit sandpaper usually wet.
4. Lightly apply the top color, in 2-3 light coats with just enough paint to cover the primer. DO NOT go thick trying to get a "wet" look. If you go too thick on any coat the paint will crack. Once cracked you are screwed, you cant just repaint it. You have to sand and fill the cracks, re-prime, etc. Then the paint will still be much more likely to crack in the same place.
5. Once the top coat is dry (varies by temp, humidity, and altitude) then clear it. I have recently been using a walmart rustoleum crystal clear enamel. It will make even the dullest paint look like glass. Thats its job. The more layers the better it looks up to like 4-5, BUT I stick with 3x because of the cracking risk. On a very flexible part I sometimes use PVA or Modpodge in a spray can (walmart craft section) because it will flex quite well.

In FL on a 70-80deg F day with 20-30% humidity I can;
1. PVA - wait 1-2hrs before priming
2. Prime - wait 30min before Top Color
3. Top Coat - wait 10min, second coat, 10 2nd, 10, 3rd
4. Clear - Wait 30min after Top then Clear. 3x coats at 1-2 min between.

This can work if the part is in the sun with good airflow. You can paint like crazy. But if its a rainy day you have to go slow. Set up some work lights (halogen) that generate some real heat and a fan on "low" in the garage as a drying station.

========

Good luck on your build. This is my second year with this build and it just gets better as you add detail! I did mine the first year in less than 2 weeks with zero sleep or work. I was unable to make the boots or gloves, but nobody noticed really. In the ed it will be dark and you will look cool. What not to skip is the lighting!

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! - Race to Halloween!

You have a few painting issues and like pep'ing it takes many attempts to get the process for painting foam, in your environment where it will come out great.

0. Take an extra 30 minutes and get a large spare piece of foam, divide it into like 6x horizontal stripes using a sharpie. At one end write what the test area is for. i.e.
I. PVA, primer, top, PVA
II. PVA, primer, top no clear
III. PVA, primer, top, enamel clear
...etc, etc. Then you will find yourself referencing this test piece many times. You will discover many things. For example the best looking one is not the best choice for parts the flex a lot, but a slightly less shiny part that does not crack is superior for the application.
1. Seal the heck out of the foam. I use a real PVA from Amazon : Helmar Craft and Hobby PVA Glue, 8.45 Fluid Ounce. I first cut it 50/50 with water, and toward the final coats barely cut it. I seal until it looks like its a solid epoxy like surface. I have also used Modpodge successfully in the glue like and spray containers.
2. Primer lightly but completely
3. On a high visibility part (i.e. helmet) you might want to lightly sand at this step with 1500 or 2000 grit sandpaper usually wet.
4. Lightly apply the top color, in 2-3 light coats with just enough paint to cover the primer. DO NOT go thick trying to get a "wet" look. If you go too thick on any coat the paint will crack. Once cracked you are screwed, you cant just repaint it. You have to sand and fill the cracks, re-prime, etc. Then the paint will still be much more likely to crack in the same place.
5. Once the top coat is dry (varies by temp, humidity, and altitude) then clear it. I have recently been using a walmart rustoleum crystal clear enamel. It will make even the dullest paint look like glass. Thats its job. The more layers the better it looks up to like 4-5, BUT I stick with 3x because of the cracking risk. On a very flexible part I sometimes use PVA or Modpodge in a spray can (walmart craft section) because it will flex quite well.

In FL on a 70-80deg F day with 20-30% humidity I can;
1. PVA - wait 1-2hrs before priming
2. Prime - wait 30min before Top Color
3. Top Coat - wait 10min, second coat, 10 2nd, 10, 3rd
4. Clear - Wait 30min after Top then Clear. 3x coats at 1-2 min between.

This can work if the part is in the sun with good airflow. You can paint like crazy. But if its a rainy day you have to go slow. Set up some work lights (halogen) that generate some real heat and a fan on "low" in the garage as a drying station.

========

Good luck on your build. This is my second year with this build and it just gets better as you add detail! I did mine the first year in less than 2 weeks with zero sleep or work. I was unable to make the boots or gloves, but nobody noticed really. In the ed it will be dark and you will look cool. What not to skip is the lighting!

thanks for all of the insight. We did actually do a few test pieces that had different stages of the prep/paint process and the test pieces came out fantastic. you mentioned using the walmart rustoleum crystal clear, do you think that if I apply this it may even out the luster of the paint on these pieces or will it still have noticeable spots? Looks like tomorro from 2-5PM is my best sweet spot for painting. It will be 70 degrees and about 40% humidity which is the lowest the humidity will get all day. I am going to try and get everything recoated with a second coat then and a third coat on the boots. I'm working on the remaking the helmet tonight. Just got everything cut out and about to start with the glue gun

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

Ok so I was up all night and it took me about 9 hours but I remade the helmet and its sooo much better now! Actually looks like Iron Man! See the pics below for comparisons to the old one.

Its still not perfect but I am happy with it for now

 

[Helagak]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

amazing what a little bit of practice will get ya, isnt it?? I built my wifes helm in a rush 2 days before my deadline. it was my third helmet. and now its my favorite yet!
you did an amazing job on that helmet. its right up there with the best foam helmets on this site. congrats brother!

 

[artbypaul]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

You've done a great job on this! One of these days, I've got to try to build my own. Again, GREAT work!

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

amazing what a little bit of practice will get ya, isnt it?? I built my wifes helm in a rush 2 days before my deadline. it was my third helmet. and now its my favorite yet!
you did an amazing job on that helmet. its right up there with the best foam helmets on this site. congrats brother!

Thanks man! things are going good so far.. with the exception of the helmet due to the late start on it I have everything painted and cleared and only three pieces needing a second coat of clear. The clear coat completely fixed the dull spots so it looks like glass! I have sealed the helmet with 5 coats of elmers and about to do the second coat of primer. I need to pick up more gold and clear in the morning first thing but the costume itself if coming along nicely. Tonight I am working on the arc reactor, the lever switches for the repulsors, and the LED eyes.

You've done a great job on this! One of these days, I've got to try to build my own. Again, GREAT work!

Thanks a lot dude! get yourself some foam and make something small to start out, just not the helmet.. trust me!

A pic after painting..

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! -Race to Halloween! PAINT STA

Okay so I managed to get the suit done in time for the big costume contest that I wanted to enter. registration was from 4-7pm and I signed up at 6:58 since I literally finished the costume just moments before rushing out the door to get to the event. Here is a pic of the helmet in progress from earlier today, and then pics of me at the event and in the parking lot. I forgot to get a good picture of me from the back.. oh well. Also the pics from the event arent as clear as I would like but hey what can ya do right.. lol. Also I probably ripped almost all of my hinges on the suit. Going to have to repair/remake all of them. I tried to add washers to the chicago screws but the actual foam pivots just ripped. Anyway, here are the pics. enjoy!

Ant

 

[STEALTH]

Re: Iron Man Mark VI Foam Suit - My first build thread! Race to Halloween COMPLETED P

Great final result. Great proportions. Glad you redid the helmet. Makes more sense now when people say "do it last" after building a suit, you'll have the experience and feel to do a more advanced part like the helmet to a better standard.

Well done.

 

[fyreant]

Re: Iron Man Mark VI Foam Suit - My first build thread! Race to Halloween COMPLETED P

Great final result. Great proportions. Glad you redid the helmet. Makes more sense now when people say "do it last" after building a suit, you'll have the experience and feel to do a more advanced part like the helmet to a better standard.

Well done.

thanks man! I am really happy with the way the helmet turned out in the end myself. Really helped to sell the costume as being more accurate. I'm already dreaming up ways to fix the pivot hinges on this one to make it more durable. All things considered, there is a lot of cracking in the paint, but I only had a few minor things that ripped, and then the arm and leg hinges. I am sure the suit would make a few events if I can fix those items to function better. I also have better quality pics coming up here shortly.. stay tuned..

Ant