Iron Man MK 6 foam armor PROGRESS PICS ADDED

Discussion in 'Marvel Costumes and Props' started by Immortal Goat, May 6, 2012.

  1. Immortal Goat

    Immortal Goat Well-Known Member

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    Hello again, RPF! I am starting a new costume project, an Iron Man MK 6 movie suit using EVA foam floor mats. I have the pepakura files, provided by Stealth on his YouTube channel (thank you, Stealth, as well as a big thank you to the original creator of the files), and I have begun cutting the pieces out. My foam mats are about half an inch thick which seems kind of thick to me, but it's all I could find in stores near me.

    Once I finish the foam build, I plan on coating the whole thing with resin, so it has a nice hard shell, and won't deteriorate the way most foam suits seem to.

    Since I have just started, and this is my first foam project, any input would be welcome! Pics coming soon. Thanks!
     
    Last edited: May 7, 2012
  2. Kevin Gossett

    Kevin Gossett Master Member RPF PREMIUM MEMBER

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    Re: Iron Man MK 6 foam armor

    You will need to seal the foam before coating it. PVA/wood glue is the most popular way to seal. Three or four coats should do the trick, then you can move on to the outer coating
     
  3. Finhead

    Finhead Sr Member

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    Re: Iron Man MK 6 foam armor

    No not correct. If your using smooth on 65D you just use it no need to seal it, that's what the resin is already doing.
     
  4. Kevin Gossett

    Kevin Gossett Master Member RPF PREMIUM MEMBER

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    Re: Iron Man MK 6 foam armor

    I stand corrected. I was under the impression the foam still needed to be sealed :thumbsup
     
  5. Immortal Goat

    Immortal Goat Well-Known Member

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    Re: Iron Man MK 6 foam armor

    Good info. Thanks. Any recommended brand of resin?
     
  6. Berserk

    Berserk Well-Known Member

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    Re: Iron Man MK 6 foam armor


    Re-read Finhead message, he tells you right there what to use
     
  7. Immortal Goat

    Immortal Goat Well-Known Member

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    Re: Iron Man MK 6 foam armor

    Ah, I thought that was a type, not necessarily the brand. Thanks for clearing that up :)
     
  8. Finhead

    Finhead Sr Member

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    Re: Iron Man MK 6 foam armor

    Sorry you may be right, just pointing around now that I can log onto the site with my pc. XRobot seals his off with the PVA first. In any test I have done with the resin I have not used any sealer on the foam and it worked fine from what I can tell. So I guess I would advise to test a small piece first see how it goes and go form there.
     
  9. kopairnik

    kopairnik New Member

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    Re: Iron Man MK 6 foam armor

    I'm not really used to those forums and I don't know if it's ok, but I'm in the same position as Immortal Goat. Since I'm just starting the same project, is there any part of the suit that would be easier to build, you know to get me started.
     
  10. Finhead

    Finhead Sr Member

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    Re: Iron Man MK 6 foam armor

    If it were me starting out again I would start with a bicep or gauntlet first test size and get the feel for it. If it's the wrong scale or whatever not a huge waste of time or material.

     
  11. bleahhh

    bleahhh Active Member

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    Re: Iron Man MK 6 foam armor

    Not my thread But just wanting To help, try te chest piece
    As the pcs are rather large and straight forward
     
  12. Immortal Goat

    Immortal Goat Well-Known Member

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    Re: Iron Man MK 6 foam armor

    I'm working on the chest piece first, but I haven't glued anything yet. Still cutting pieces out, but I'm already liking this method way more than making it out of paper. Pics soon.
     
  13. Onephattsi2

    Onephattsi2 Well-Known Member

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    Re: Iron Man MK 6 foam armor

    im also i first timer... i started out with a forearm... it taught me a lot for sure....

     
  14. Immortal Goat

    Immortal Goat Well-Known Member

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    Re: Iron Man MK 6 foam armor

    [​IMG]

    Here's what I have of the chest so far. The glue is a little messy around the seams, but since I'm going to put a shell of resin over this, I'm not worried.
     
  15. ValTroX

    ValTroX New Member

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    Yo seem to have done a good job, I'm also trying my first foam project(and project overall). My angle cuts aren't going so well :(. I just ordered a mat cutter, as suggested by Stealth to try to get started with my MK7 armor :).
     
  16. Immortal Goat

    Immortal Goat Well-Known Member

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    [​IMG]
    [​IMG]

    Couple shots of the completed chest, I'll have the back piece done later tonight, pics probably tomorrow.
     
  17. Immortal Goat

    Immortal Goat Well-Known Member

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    [​IMG]

    Shot of the back piece. Some of the corners aren't very clean, so I'm going to use modeling clay to sharpen them before I put the resin on. Also, the thickness of foam I have is a little thick for the rest of the armor. Anybody know where I can find 1/4 inch foam online or in stores?
     
  18. CaptainVermont

    CaptainVermont New Member

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    Check craft stores? It will come in colors, but 1/4 is approximately 6mm
     
  19. Immortal Goat

    Immortal Goat Well-Known Member

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    Thanks for the tip :)
     
  20. payton paison

    payton paison Well-Known Member

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    I found Best Step 1/4 EVA foam at Sears.
     
  21. Immortal Goat

    Immortal Goat Well-Known Member

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    [​IMG]

    [​IMG]

    Shots of me wearing the pieces I completed so far. Found thinner foam sheets (6 mm) and I'm working on the biceps right now.
     
  22. Immortal Goat

    Immortal Goat Well-Known Member

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    Bumping with progress. Finished the biceps and the gauntlets, working on helmet now. I will have pictures in the next couple of days.
     
  23. Nahatma

    Nahatma New Member

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    looking good, did you re-sized the templates?
     
  24. nestor300

    nestor300 New Member

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    Hello,
    just wanted to say that its looking pretty good so far and i was wondering if you re-sized the templates? im just asking because when i try to re size them the a lot of extra parts appear
     

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