Iron Man Mk VI for Three Year Old (pic heavy)

[Tigerblood]

Re: Iron Man Mk VI for Three Year Old

Thinking about the gloves tonight, do you think I can brush on casting resin into the fingers to harden them instead of using fiberglass? They'll be so tiny, I don't think I can get fiberglass in an area that small.

I found a local source for Smooth-Cast 300 and I'm gonna get some tomorrow. They don't carry the whole line, but I figure 300 should do for most applications. I'm also gonna pick up some Oomoo 30 silicone. I don't have a use in mind yet, but I want some just the same.

I wouldn't use Smooth-Cast to brush on anything. Filling the soles I'd recommend it and even that I'd still go with casting resin/"surfboard" resin to fill the boots.

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

When I went to buy the Smooth Cast 300, they also had a Smooth-On product called Shell Shock. It's "brushable plastic." I tried it on one of the finger pieces and it worked beatifully! So that's how I'm going to harden the small pieces for the fingers.

I'm still running into some issues with scaling the palm and fingers. I'm gonna mess around with it more tonight. Good thing is that I can pep a finger in like 15 minutes so it's not a big deal to keep trying till I get it right.

My plan to connect the fingers together is to glue or resin in two thin elastic bands running through the corners of the fingers, that way they don't stretch across the knuckle, and it has some stretch to it. I know some people mentioned fishing line or guitar strings at the pivot points, I might give that a try too.

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

Weekend Update:

It's been raining all weekend, so I haven't been able to get much done. I did some fiberglass edge cleanup on some of the pieces that I've glassed and laid down the cloth (but not the resin) on some more pieces, that way when the humidity dies down they'll be ready to go.

So. Since I was stuck indoors I decided to do some other work. Namely hands and hip pods. I made about 4 sets of fingers before I finally decided on a size that would and have enough cushion for gloves and hardening. Here's the final size. Talk about fat fingers!

Then I decided to take a cue from Xrobots and try casting the hip pods. I pepped the very tiny piece and did a silicon mold using Smooth-On Oomoo 30, then cast it in Smooth-Cast 300. The rubber leaked through some pieces of the pep, and also when I cast it, it tore out some of the details. With that monumental failure behind me, I decided to try pepping the large part and sculpting the details in clay. The results were much more promising and with some cleanup I think will come out great!

Only 6 weeks to go and I'm a bit worried!

 

[P4r4dox86]

Re: Iron Man Mk VI for Three Year Old

You'll do fine mate! You've managed to do so much in such a relatively small timeframe already, I think you'll make your deadline .

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

Today's Update, got a lot of fiberglass work done this week, I'd like to have all of the pep pieces glassed by the end of the weekend. It's a time consuming and messy process, but I think I've got a rhythm down.

1. Cut a bunch of 2" x 3" sections of fiberglass cloth
2. Spray inside of piece with spray adhesive
3. Lay down fiberglass cloth
4. Brush in resin
5. Let cure
6. Cut off any excess fiberglass from edges
7. Feel for any bubbles between fiberglass and cardstock and mark them
8. Dremel down the fiberglass around the bubble area
9. Lightly dremel the whole piece inside
10. Repeat 1-6
11. Profit.

I get several pieces ready to go before I start brushing in resin, that way I can move onto the next piece if the resin hasn't jellied.

I'm using what I believe to be 6oz 3M fiberglass cloth from Home Depot. I read somewhere that about 20oz was good for strength, but since this suit is smaller 12oz (two layers) seems to be pretty good.

After I get two layers, I'll cut off the excess then shape the piece using a heat gun.

 

[docholiday78]

Re: Iron Man Mk VI for Three Year Old

wow this is gnna be amazing..reminds me of this

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

End of weekend update:

I got most of the suit hardened. Just lacking some detail pieces like foot flaps and boots, hands and hand plates, and spine. Here's a test fit of the left arm with chest and back:

I may shorten the top of the bicep a bit, I haven't decided. I need to set up the strapping to see if it can be held up high and tight enough.

I also need to do the foam pieces and the helmet. I've decided I'm going to find a different way to harden the helmet other than fiberglass resin. I may use casting resin/fiberglass or the shell shock I got, haven't decided yet.

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

Weekend update:

I really fell short this week, I wasn't feeling well because of allergies and ended up taking most of the week off of costume work (which was stupid considering how much work I have left and how little time there is).

I thought more about the boots and decided that my "screw post" method described above probably wasn't going to cut it so I devised a new method.

I cut the bottoms out of the main shoe and am going to fiberglass it to the other two pieces on the inside, then fill the soles with casting resin, then shape a piece of foam to fill the gap, then fiberglass the bottoms of the shoes back in. Then I'll add the real shoe and resin that in as well. Here's a couple pics of where I'm at on the shoes:

I also received the gloves that I ordered today. I originally intended to have my wife sew some small gloves out of elastic fabric, but it ended up being an epic fail. I was contemplating what I could do then I did some creative searching and found these:

They are satin elastic *wait for it* flower girl gloves from PinkPrincess.com. How un-Iron Man can you get! But they look like they'll do the trick perfectly.

I've got an offer of help two days a week from my brother, so we'll see if we can get this knocked out before Halloween. I know it's possible, I just have to really buckle down for the home stretch.

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

Big Boot Update!

Ok, so I made a lot of progress on the boots tonight. I poured the resin and got the foam pieces cut and I'm really happy with how it all came out. I also cast the second hip pod. Here's the pics:

Fiberglassing the backs to the main shoe:

Before casting (I taped up the whole boot to avoid any leakage):

After casting:

Foam inserts:

The foam is high density, but I'm still going to try to compress it a bit when I fiberglass in the heel platform. The total weight right now is 330g. My size 12 running shoe is 400g. I'm aiming for it to weigh about that much.

 

[Darth Ronnow]

Re: Iron Man Mk VI for Three Year Old

Howdy,
This is just too cool. I like seeing Dads making their kids wicked cool replica costumes.
Great work.thumbsupthumbsupthumbsup
Cheers,
Clint

 

[TrioxinKustoms]

Re: Iron Man Mk VI for Three Year Old

awesome!

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

Final Boot Update:

I'm spending so much time on the boots because I figure a stable foundation is probably one of the most important parts. With that said, I'm pretty happy with the results.

Casting heels:

Casting toes:

Testing:

Video Link - Stomping Around

And a bonus:

 

[avallarino]

Re: Iron Man Mk VI for Three Year Old

So cool!

 

[Kevin Gossett]

Re: Iron Man Mk VI for Three Year Old

And a bonus:

It's like a 1:3 maquette! :lol

This looks completely awesome :thumbsup

 

[heavymetaliron]

Re: Iron Man Mk VI for Three Year Old

This is so cute! We are at similar stages of building our suits and your thread continues to inspire me. Keep up the good work!

 

[kirobel]

Re: Iron Man Mk VI for Three Year Old

Best.Father.Evar!!

 

[dracoangelus]

Re: Iron Man Mk VI for Three Year Old

Amazing job men.

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

Ok, I'm running out of time but I got a lot done today. I got my brother to help and we applied body filler to most of the suit. I also got a few pieces sanded. Here's the pics:

Sanded:

Bondo'd:

To Bondo:

 

[ShojiSan92]

Re: Iron Man Mk VI for Three Year Old

Wow i cant wait to see this!!!! this reminds me of that voltron girl that her dad made her!!!

 

[Incinorator]

Re: Iron Man Mk VI for Three Year Old

I'd like to see that, got a link? (Search didn't come up with anything)