Iron Man Mk3 foam suit fitting issues. (WIP pic heavy)

Psych007

New Member
Hey guys, I'm new to the forum and just started building this suit a 3 weeks ago. Have never done anything like it before but I can say that I'm hooked to this hobby and can see myself doing a few more suits in the future.. :)

I started googling for a Iron Man suit for a costume-party this summer and stumbled upon a few tutorials that got me very interested. Studied some pep with glassfiber and bondo. (Gonna try that out later on)
And suddenly Stealth's Hero-tutorials popped up on the tube. And I got extremely impressed that you could do such a nice job making a suit by using foam!
So after alot of hours reading through alot of threads here at RPF I started out on my build.
Did some trial and error first (and still do :p ) but now I've got a problem that I can't find an sure answer for so I'm pleading to you guys to help me out. :)
I'm 180cm/5ft11 tall and weigh 75kg/165lbs so no bodybuilder. :)
And I've used Dancin_fool's foam templates for the build without any scaling adjusted. Since it should work for a guy 5.10-6.1 I gave it a go without scaling.

Today when I took a look at my chest/back-piece I just got scared of how big it looked all of the sudden and compared to alot of chests it does stick out alot from my thin chest. How does the size look compared to my body and what could I do to adjust the scale if that's the solution?

809ABD5D-0FBB-4F9E-AC24-DE07AF4896BF-6144-00000C7AA18564CC_zps01e9ab02.jpg


The back-piece is flush to my back and the chest sticks out about 10cm/3,94inches.
42C7E04B-853C-450E-B5A3-871890EEA666-6144-00000C7AA5EABF73_zps4c410347.jpg


It doesn't look too bad from the front imo. And what about the size of the arms, still no scaling and theyr'e not flush at all to my spaghetti-arms :p
B095C3A0-82C4-485E-9EC6-07A8926916ED-6144-00000C7A8F1DC167_zpsef0ca27a.jpg


Here's a pic without the arms to easier see the chest sticking out.
49CACB26-BCD0-4077-83D9-C1A5AF08DFCB-6144-00000C78A76E5A7A_zpsa1bc08d8.jpg

E194AE18-1540-4F38-854A-B473BC616D1E-6144-00000C78B7D66CBF_zps68adf604.jpg


Back-piece.
EFE0C746-969A-4F70-955D-16C64264A05B-6144-00000C7BDD80E2A3_zpsee175710.jpg


Back-piece on before flaps.
650D3C6C-22D7-4AED-A717-9AD774BAAB2F-6144-00000C7BE2E1755D_zps5598f641.jpg


Ande here's just my first try before I read up about foam-tips and trix.. :)
Before.
056B9846-3100-4267-9E0D-BF5FC1BBF254-6144-00000C7AFDE98FDE_zps92d2915b.jpg

After.
A63A2C47-C8E6-42FC-B697-AE0B1CD0909D-6144-00000C7AF96980EE_zpsea38e411.jpg


I still have alot to learn and skill to be improved but it goes better and better. :)

Btw I've been using 12mm foam for the chest and back and 6mm for the arms. If I could find 6mm eva-foam for a normal price here in Sweden I would go with that but as there isn't much to choose from I will go with the 12mm for the bigger peices.
The 6mm I've used untill now comes in 30x46cm sheets and cost 5,5$ each which will be quite expensive in the end if I would do the whole suit in it.
Oh well that's enough blabbing for now, hope to get some advice on the chest/back-piece and size overall.
Cheers.

/Stefan
 
OK then time for an update! :)
Alot have happened since I started the thread, since I didn't get any answer I just continued building more pieces to get the overall look and it looks pretty good.

I made a duct tape-mannequin to get something to attach all the pieces to and get a better look how they will fit on me and with eachother. Thanks Stealth for the tube-tutorial! :)


A few peices fitted on to try it out, my new foam helmet didn't fit since I have a piece of foam glued in it for holding shape until I can get it covered in Smooth-on 65D for a rigid shape.


I had to remake the neck a few times to get it the right size, practice makes perfect. ^^
Made in 2mm foamies.


The shoes are Robo3867's templates.


My sneakers fit pretty good in them. :)
I'm planning to find a solution to get em to fit better to them tho, in worst case I'll just take an old pair of sneakers and glue em.


I made a new helmet of foam instead of pep and I like this one much better but there's always space for improvement. :)
I'm searching for something to use for getting the helmet top in the round shape in one piece by heating (Saw an tutorial by using two toy helmets). Haven't found anything useful around here yet tho.



Got the shoulders done but I'm probably gonna redo em and trying getting a more rounded shape. Not really happy with em.


Cod-piece. It didn't take long before I cut off the piece connecting between the legs. :p


The spine connected to the back of the abs. Hadn't got the abs fully done on this picture.


Front of abs.


I also made 2 hip-dongles of foam. The first idea was to make it in something else or buy a set of em but I'm pretty happy with the result.


The two thigh-pieces. I have some shaping to do so they'll look and fit better.


And I just finished the calves a few hours ago. Didn't really get the right bend on the upper back-flap but I'm happy with the result.
And I must say that the thighs and calves were ALOT harder to do than I thought. :D


I'm sorry for the long and pic-heavy post!
Now I'm off to do some fitting, adjusting and then I'll start with the hands unless I start with some PVA-glue painting, sounds like fun. ^^
Peace out!
 
Looks good! Keep up the good work. To answer your question, I believe that the chest is supposed to stick out a bit to allow for the arc reactor and to give you that "big chest" look.
 
Looks good! Keep up the good work. To answer your question, I believe that the chest is supposed to stick out a bit to allow for the arc reactor and to give you that "big chest" look.

Yeah I found that when I made the abs and got those on the dummy with the chest it looked alot better. :)
 
Nice work, everything looks very precise. I did some modding on my Rider suit, and made the midsection from sintra. It is flexible, strong, and very light. You may want to consider this because sintra will not crease, or buckle. That is the one problem with painted foam, it can crease, and ruin the paint up. Again, great work, much success to you.
 
Looks awesome man :) ive been doing a lot of reading and lurking on here lately too as i want to start my own foam Iron Man suit too soon.
 
Looks great! To be honest I think the chest piece looks fine, it might look big now but when you have the rest of the suit on it'll probably look more in proportion as the rest of the suit will give you more bulk elsewhere, so I'd say don't try to adjust it until you've tried it on with the other pieces too. Also, your duct-tape man dress up as Iron Man made me lol for some reason XD
 
Thank you guys!

A friend came over briefly today so I got some help from him to dress up the mannequin with almost the entire suit. I also ordered some nylone band and plastic clips for starting assembling the parts properly.


The parts doesn't fit that good yet but I'm getting there.. :)
 
Made a pair of handguards of 2mm foamies yesterday. Will see if they'll hold for some abuse or if I need to find thicker foam, 6mm feels a bit too much..

 
foam building skills are looking pretty swank bro.
its gonna look real nice and clean after paint. as long as you keep those edges nice and true and glue free. :)
 
Looking great, I think the trial and error has a big payoff once perfected :)

Actually I had to do a double take at your images.....you remind me of Ewan Mcgregor and the guy from lost and LOTR :)
 
Looking great, I think the trial and error has a big payoff once perfected :)

Actually I had to do a double take at your images.....you remind me of Ewan Mcgregor and the guy from lost and LOTR :)

Thanks man, yeah trial and error really is needed to get better at it. :)

And thanks for the compliment! :D
Dunno who you refer to in Lost but I guess you mean Gimli in LOTR. ;)
 
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