Iron Man MK4 Pep and Cardboard

[Bandiet]

Being a huge IM fan and having seen all the amazing builds posted over the years, I thought I'd give it a go. Initially it was only going to be a bucket build, but I've started with a cardboard suit as well... so I'll see how it goes. Here are some pics of the bucket build so far...

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[Hoplitespear]

Damn, the more and more i see these pep -> bondo helmets the more and more i wanne throw away my foam one and build one of these. They are so nice, your symmetrie work is verry nice. Did you have any prev experience with bondo n such? Can't wait to see the end result!

 

[Bandiet]

Hey Hoplitespear... Thanks, to be honest, this is the first time I've worked with fibre glass and body filler. It's been a hell of a learning process, but I've taken my time ( lots of sanding and bondo and sanding and bond ).

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[Hoplitespear]

Hey Hoplitespear... Thanks, to be honest, this is the first time I've worked with fibre glass and body filler. It's been a hell of a learning process, but I've taken my time ( lots of sanding and bondo and sanding and bond ).

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After my full foam suit, I'm gonna tackle a pep- bondo helm, trying to make it perfect, opening faceplate etc... . Gives me some hope it can be learned

 

[Bandiet]

After my full foam suit, I'm gonna tackle a pep- bondo helm, trying to make it perfect, opening faceplate etc... . Gives me some hope it can be learned

Cool, keep me in the loop. You'll see it's not as tough as it looks, just look for guys doing decent tutorials and you'll have decent results... Allow me to give you the first bit of advice : The old saying of "less is more" applies heavily to the bondo stage. Thin layers, one section at a time goes a long way in keeping the form as sharp as possible. Not to mention less time spent sanding and a lot less bondo wasted ( I learnt this the hard way ). Looking forward to seeing your thread....


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[Bandiet]

Update...
I've had a hard time getting the ears nice and round... I saw a post some time ago where wood was used, so the pep ears have been discarded and the wood trials have begun. I seriously need to invest in the right tools for the job.
Also started cleaning up the back... doesnt look like it though.

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[glennh]

Looks real nice and crisp in the last pic first post. . Faceplate looks superb.

 

[Ironman4lif]

Hey man awesome work so far!!!
are you from South Africa ?
Will you making casts?

 

[Bandiet]

Looks real nice and crisp in the last pic first post. . Faceplate looks superb.

Thanks Glenn, a ton of sanding and still a ton to do....


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[Bandiet]

Hey man awesome work so far!!!
are you from South Africa ?
Will you making casts?

Hi Ironman4lif, thanks, yip, down in Richards Bay... I think this makes 4 SA builders on the RPF ( That I've seen ). I'm still in two minds about casting this build. I'll see once it's complete, if I feel its cast worthy. Right now I'm trying to see which is going to be the easiest way for the rest of the suit. The cardboard is faster ( done the chest, back and abs so far ) but it's going to take a lot of resin, filler and about ten tons of sandpaper to get it looking good.

If I remember correctly from one of your threads, you are planning on getting a 3D printer some time. I think I'll be doing the same, since I've starting 3d modeling with Blender as well, but that will be a bit later this year.

I'll let you know if I do a cast...


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[Bandiet]

Finally got the ear pieces on... not really happy with them though. I've been trying to get the colors matched as close as possible, but the local paint stockists dont keep a huge selection. Will have to look when I'm down in Durban again. Any how... this is where things stand as of today.
Ignore the messy jaw... still have to get the glue from the masking tape cleaned off.

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[Bandiet]

Thanks Glenn, a ton of sanding and still a ton to do....


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Oh, by the way... Thanks for the tip you gave on your thread regarding using resin in tight spots to get a flat finish. I used the tip for the back end of the helmet's three " indents "... Worked like a charm.


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[boneheart69]

Wow, Nicely done and smooth! I bet this requires a loooot of sanding, measurement and patience! looking forward for more updates!

 

[Bandiet]

Wow, Nicely done and smooth! I bet this requires a loooot of sanding, measurement and patience! looking forward for more updates!

Thanks, yeah... A loooot of sanding, and then some more LOL. I am currently reworking the the helmet, I picked up on some imperfections on the back side after painting it, so there's still a little work to be done before I'm happy with.

I've been watching your thread very closely... I was in two minds wether I should use foam or cardboard as a base for the rest of the suit. I opted for cardboard and have built pretty much the entire upper body ( will get some pics up soon )... But now you've got me rethinking the foam process, your build's really coming out nicely. I've still got a roll of 6mm foam lying around, I might just give your technique a shot this weekend. I will let you know how it goes...

Thanks again for the compliment...


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[Bandiet]

Ok... so I'm basically done with the helmet, just some fine tuning to do.

Now it's time to move on to this monstrosity. Still not sure if I'm going to get the results I'm hoping for, but if you don't do it you wont know I suppose.
I should start applying the first resin coat on the chest tonight...

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[Bandiet]

Making slow progress on the chest piece... but must say I am fairly happy with how it's going so far. I do however think that I will be pepping the arms and legs instead of using cardboard. I've built one of the thighs with cardboard and it is definitely not worth using.

Here's some pics of my progress... still alot of filler and sanding to be done, but I think it's taking shape.







Tonight, We Sand!!!! ( and tomorrow... and Sunday... )

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[boneheart69]

Ok... so I'm basically done with the helmet, just some fine tuning to do.View attachment 332377
View attachment 332378
Now it's time to move on to this monstrosity. Still not sure if I'm going to get the results I'm hoping for, but if you don't do it you wont know I suppose. View attachment 332380
I should start applying the first resin coat on the chest tonight...

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Judging on the finished helmet, oh definitely you will get the result, patience is the key..especially the sanding part..oh gee

 

[Bandiet]

Hell Winter Sucks..... I'm really not getting much time in to work on the project. My workshop is way to cold at night to work, so I have to try steal time away from my other comitments to get something done.

Some small progress pics, just to show the project is'nt dead... just moving slow.
View attachment 341412


Sorry... couldn't resist

Got started on the back... hope to have the abs/cod piece, brace amd shoulders fibreglassed by the weekend... weather permitting.

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[Bandiet]

Oh... almost forgot. I got some clear casting resin for the Arc Reactor ring, just need to make a plan with some parts for the rest of the reactor...

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[megacity1]

Is the card board better at holding shape and easier to work with when applying resin?