Iron Man Mk42, completed foam.

kibosh said:
Man. That is some fabulous work. Great job! How durable is a suit like this? Will you be able to get several wearings out of it? It seems like the foam will bend and crack the paint. Fascinated by this whole pep/foam process....

Any pictures of the process you used to cast your helmet?
Click to expand...

Durability is... medium. I'll get several uses out of it. There's no "death" point, it will just get slightly more worn out every time, and I'll think it looks ruined long before people stop thinking it looks awesome. At least that's what happened with the mark 6 I build last year.

The foam does bend, but the advantage of the glue-plasti dip-paint method is a slight flexibility to the paint. Minor crease lines appear in places that it gets bent, but it doesn't really crack.

I didn't take any process pics of the mold/casting process, but I still have the mold of the helmet, I can show some pictures of that later if you're interested. It's nothing different from what hundreds of others on this site have done though.
 
WOW! That looks really amazing man. I'm gonna attempt to make a helmet and suit soon but I have no idea what I'm doing lol What did you use to glue the foam together? This will be my first time making anything like this so I'm thinking if making a paper one first to get the feel for it would be a good idea? Where did you find the link to the files you used?
 
Re: Iron Man 3, Mark 42 foam build. Legs added Oct.14

How did you cast the helmet and what did you use?
 
Re: Iron Man 3, Mark 42 foam build. Legs added Oct.14

Jersy said:
WOW! That looks really amazing man. I'm gonna attempt to make a helmet and suit soon but I have no idea what I'm doing lol What did you use to glue the foam together? This will be my first time making anything like this so I'm thinking if making a paper one first to get the feel for it would be a good idea? Where did you find the link to the files you used?
Click to expand...

I used a hot glue gun with a precision tip to glue everything. This one here. I personally think that foam is easier than paper. The files I used are a combination of those created by Helagak and Jackieisrockin. All of the ones I used were unfolded by Ironmaided. The helmet file is the one that JFCustom has in his huge foam pepakura thread.

Jersy said:
How did you cast the helmet and what did you use?
Click to expand...

To cast the helmet, I first coated the foam helmet in the glue and plasti-dip layers that I use for painting. I work for a sculptor, and we use silicone for all of the molds we make. He let me use that silicone at cost. And while it's expensive to buy, he gets in in bulk so I only used like $15 of silicone. I built a two part shell out of plaster full of hemp to give it rigidity. After that, I roto-cast (pour in the resin, rotate around to coat evenly) the helmet using a 2-part resin from Specialty Resins.
 
Great job Zlurpo! But I have a question..how tall are you?? 'Cause I don't know how to change the scale value for my height (1,80m or 5'9''/6')..I'm "studying" the Helagak's files, but I need some help :confused
 
Last edited by a moderator:
RickyPizzi said:
Great job @Zlurpo! But I have a question..how tall are you?? 'Cause I don't know how to change the scale value for my height (1,80m or 5'9''/6')..I'm "studying" the Helagak's files, but I need some help :confused
Click to expand...

I'm pushing 6'3" (190cm), so I had to change most of the pieces. Some of them I made multiple times (Helagak has said that the scale is not 100% consistent for all his pieces). But mostly I would just measure the length I needed, and adjust the file accordingly. So for the forearm, I measured from where I wanted the joint to be to where the wrist would go, and put that dimension into pepakura designer.
 
Zlurpo said:
I'm pushing 6'3" (190cm), so I had to change most of the pieces. Some of them I made multiple times (Helagak has said that the scale is not 100% consistent for all his pieces). But mostly I would just measure the length I needed, and adjust the file accordingly. So for the forearm, I measured from where I wanted the joint to be to where the wrist would go, and put that dimension into pepakura designer.
Click to expand...

So you are Iron Man with Iron Monger's dimensions ;) Thank you mate!
 
Not sure how I missed this before, but great work on your suit. You're build is pretty similar to mine; Being a thin guy actually paid off for once, fitting my stuff so it looks 'right' on me :lol Nice job!
 
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