Ironman Costume for 5yr old - LINKS on PAGE 1 - tips & important bits
- Thread starter indiefilmgeek
- Start date
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/19
Thanks, and good luck with your scarlet spider!
*****
Does anyone have any pictures of the hardware they used for the knee joint? I was planning on re-enforcing the foam pieces around the joints with epoxy and then using binding posts (which I used for Mikey's elbow joint - after referencing what MightyJohn did for his Ironman elbows), but I'm open to any other ideas.
Thoughts or Ideas?
Thanks, and good luck with your scarlet spider!
*****
Does anyone have any pictures of the hardware they used for the knee joint? I was planning on re-enforcing the foam pieces around the joints with epoxy and then using binding posts (which I used for Mikey's elbow joint - after referencing what MightyJohn did for his Ironman elbows), but I'm open to any other ideas.
Thoughts or Ideas?
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/19
Long night again yesterday...
Got some rough sanding done on the sole of the boot. Unfortunately, I couldn't find my finishing glaze (the softer bondo I use for the final smoothing and minor corrections). So, that piece just to has to sit until tonight, when I will (hopefully) have a new tube of putty.
*****
After that work, I dove into working on the fabric under-armor I'm constructing for the suit. I was very lucky to find a nearly perfect color-match to the red metal of the suit in satin. So, after finishing up the pattern on Monday night, I finally started gluing down the red satin material to the black under-armor (in this case it's a child's leotard).
Here is the first panel glued down. (ignore the 'bumpiness' of the material - it's up against a duct-tape dummy which isn't at all smooth).
The goal is to make the ab section out of four panels that conform generally to the section of ab armor seen in the Ironman suit. I figure I can get smoother sections and keep some of the stretchy nature of the under-armor if I break these sections up and leave a small gap between them. Since these 'gaps' are where the real armor has plate divisions, I think it will look pretty natural.
Here is the what the panels look like all glued down...
I'll need to have Mikey put this on now so I can confirm I've got the panels properly positioned (dear Buddha I hope so). And then I'll mark out where I will paint (fabric paint) the plate lines on each of these ab sections so it looks segmented - like the real armor.
This is a bad picture (poor lighting), but you can can sort of see how the color works pretty well with the chest armor...
...And then I buckled down and continued work on the foam lower leg armor.
Here is a picture of the parts traced out to be cut out of the EVA 3mm foam. This is just the left and right calf-sections of the lower leg. As I've mentioned before, I mark these up quite a bit. The main marking you'll see is a small 'L' or 'R' in a circle -- which lets me both which leg it's for, but also what side of the piece is the 'facing' side (the outside face).
And here's where I got last evening (early this morning)...
That's mostly done... and it's just the left lower leg. I've got the parts for the right one cut out already, so it should be faster for me to build that one up.
After I finish up both lower-legs, I'll get to work on the thighs for both legs (and then their connection points).
Have a great Wednesday!
:thumbsup
Long night again yesterday...
Got some rough sanding done on the sole of the boot. Unfortunately, I couldn't find my finishing glaze (the softer bondo I use for the final smoothing and minor corrections). So, that piece just to has to sit until tonight, when I will (hopefully) have a new tube of putty.
*****
After that work, I dove into working on the fabric under-armor I'm constructing for the suit. I was very lucky to find a nearly perfect color-match to the red metal of the suit in satin. So, after finishing up the pattern on Monday night, I finally started gluing down the red satin material to the black under-armor (in this case it's a child's leotard).
Here is the first panel glued down. (ignore the 'bumpiness' of the material - it's up against a duct-tape dummy which isn't at all smooth).
The goal is to make the ab section out of four panels that conform generally to the section of ab armor seen in the Ironman suit. I figure I can get smoother sections and keep some of the stretchy nature of the under-armor if I break these sections up and leave a small gap between them. Since these 'gaps' are where the real armor has plate divisions, I think it will look pretty natural.
Here is the what the panels look like all glued down...
I'll need to have Mikey put this on now so I can confirm I've got the panels properly positioned (dear Buddha I hope so). And then I'll mark out where I will paint (fabric paint) the plate lines on each of these ab sections so it looks segmented - like the real armor.
This is a bad picture (poor lighting), but you can can sort of see how the color works pretty well with the chest armor...
...And then I buckled down and continued work on the foam lower leg armor.
Here is a picture of the parts traced out to be cut out of the EVA 3mm foam. This is just the left and right calf-sections of the lower leg. As I've mentioned before, I mark these up quite a bit. The main marking you'll see is a small 'L' or 'R' in a circle -- which lets me both which leg it's for, but also what side of the piece is the 'facing' side (the outside face).
And here's where I got last evening (early this morning)...
That's mostly done... and it's just the left lower leg. I've got the parts for the right one cut out already, so it should be faster for me to build that one up.
After I finish up both lower-legs, I'll get to work on the thighs for both legs (and then their connection points).
Have a great Wednesday!
:thumbsup
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indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/21
I must be getting tired... I don't feel like I got nearly as much done tonight as the last few nights. :sleep
I did get Mikey into the under-armor with the new ab fabric on it (to make sure it fit and looked OK). I think once the chest and abs are detailed, this will look pretty good.
However, the spray-glue just didn't want to keep the satin down, so I spent a bit of time this evening hand-stitching the edges of the panels. Hopefully, that will keep it in place.
I don't think it very noticable (unless you're very close to it)...
*****
After playing with needle and thread, I worked a bit on the lower legs again. They STILL aren't 100% complete, but they're CLOSE!
Nite all!:thumbsup
I must be getting tired... I don't feel like I got nearly as much done tonight as the last few nights. :sleep
I did get Mikey into the under-armor with the new ab fabric on it (to make sure it fit and looked OK). I think once the chest and abs are detailed, this will look pretty good.
However, the spray-glue just didn't want to keep the satin down, so I spent a bit of time this evening hand-stitching the edges of the panels. Hopefully, that will keep it in place.
I don't think it very noticable (unless you're very close to it)...
*****
After playing with needle and thread, I worked a bit on the lower legs again. They STILL aren't 100% complete, but they're CLOSE!
Nite all!
:thumbsup
mizuno hadouken
Well-Known Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/22
Good work! I love this build. Learning a lot from it!
Good work! I love this build. Learning a lot from it!
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/22
As always your work is amazing. I like the idea behind the fabric for the abs, especially for a child. I think the seems make it look like section lines so they actually work out. Once you paint the rest of the detail on it will look awesome. Keep it up, your are almost done. :thumbsup
As always your work is amazing. I like the idea behind the fabric for the abs, especially for a child. I think the seems make it look like section lines so they actually work out. Once you paint the rest of the detail on it will look awesome. Keep it up, your are almost done. :thumbsup
Dannicelook
Well-Known Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/22
u're incredible with this build!! congrats!
i sent u a PM
regards! and keep building! i'll follow this amazing work 'till the end!!
u're incredible with this build!! congrats!
i sent u a PM
regards! and keep building! i'll follow this amazing work 'till the end!!
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/22
Thanks - so am I! I'm just happy to have a place to share!:thumbsup
Just replied. If you have any other questions, please feel free to drop me a line!
Thanks for the encouragement! Some days I feel like I have a ton of stuff still to do and other days I feel like I'm just starting to see the light at the end of the tunnel. I very much feel like I've started a big final push to get this suit done before Halloween - It will be tight, but I think I can still do it (and keep the quality level the same as when I started the project).
Expect another update tonight!
Thanks - so am I! I'm just happy to have a place to share!
:thumbsupJust replied. If you have any other questions, please feel free to drop me a line!
Thanks for the encouragement! Some days I feel like I have a ton of stuff still to do and other days I feel like I'm just starting to see the light at the end of the tunnel. I very much feel like I've started a big final push to get this suit done before Halloween - It will be tight, but I think I can still do it (and keep the quality level the same as when I started the project).
Expect another update tonight!
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/23
My wife is sick. :confused So I've been very occupied over the last 24 hours with kid-wrangling. Luckily after getting everyone to bed I was still able to get a little bit more done on the suit.
I hit the bottom section of the boot with some finishing glaze (or finishing putty).
If I can sand this and get it 'close-enough' tonight, I'll get this puppy cast and two copies poured this weekend.
****
The only other thing I got done was the last annoying sections of the lower legs. I ended up with something WAY out of alignment back there. I'm not sure what I effed up, but I had a LOT of extra material on the top section of the lower leg compared with the lower section of the lower leg. The back of the calf has some cool details, but I ended up deciding to simplify that area quite a bit, and then modifying part of the top to get them to work... I just really hope I haven't messed up the alignment of connection points to the thigh section by making these changes.
Here's how the back of the calves came out...
Not spectacular, but as long as it works, I'll be ok with them.
In this pic you can see the trimmed down section (wedge-shaped) piece on the upper calf section (left piece) where I modified the shape so the top and bottom sections matched up better.
This morning I did a quick test-fit just to make sure everything was working...
*****
The only other thing I did was to begin considering how to create my foam templates for the last piece (the thigh armor).
I'm really struggling with this piece... I'm not sure why, but I'm just not 'seeing' how some of these sections would be best constructed out of foam. I know everyone talks about what a pain the arse the thigh pep piece is to build, so I guess that just translates into a difficult piece to modify into foam. :rolleyes
Here's my work so far, although most of these markings are the 'easy parts'...
That's it for now...
I'm hoping to get a lot done this weekend -- Let's hope I didn't just jinx myself! :behave
My wife is sick. :confused So I've been very occupied over the last 24 hours with kid-wrangling. Luckily after getting everyone to bed I was still able to get a little bit more done on the suit.
I hit the bottom section of the boot with some finishing glaze (or finishing putty).
If I can sand this and get it 'close-enough' tonight, I'll get this puppy cast and two copies poured this weekend.
****
The only other thing I got done was the last annoying sections of the lower legs. I ended up with something WAY out of alignment back there. I'm not sure what I effed up, but I had a LOT of extra material on the top section of the lower leg compared with the lower section of the lower leg. The back of the calf has some cool details, but I ended up deciding to simplify that area quite a bit, and then modifying part of the top to get them to work... I just really hope I haven't messed up the alignment of connection points to the thigh section by making these changes.
Here's how the back of the calves came out...
Not spectacular, but as long as it works, I'll be ok with them.
In this pic you can see the trimmed down section (wedge-shaped) piece on the upper calf section (left piece) where I modified the shape so the top and bottom sections matched up better.
This morning I did a quick test-fit just to make sure everything was working...
*****
The only other thing I did was to begin considering how to create my foam templates for the last piece (the thigh armor).
I'm really struggling with this piece... I'm not sure why, but I'm just not 'seeing' how some of these sections would be best constructed out of foam. I know everyone talks about what a pain the arse the thigh pep piece is to build, so I guess that just translates into a difficult piece to modify into foam. :rolleyes
Here's my work so far, although most of these markings are the 'easy parts'...
That's it for now...
I'm hoping to get a lot done this weekend -- Let's hope I didn't just jinx myself! :behave
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/23
Just a bit more work tonight...
I did some sanding on the hardened boot sole. I wish I could have primed it tonight, but apparently I don't have any more filler primer laying around.
So, I went ahead and installed the vertical support pieces in the heel. That should provide plenty of support, without adding the weight of a completely solid heel.
And here is the shoe test-fit... As stated before, my plan is to cast and pour two resin copies of the sole of the boot and then build a foam boot top around the slip-on shoes we picked up for $6.
*****
And I also finished up designing my paper pep templates for the thigh armor. I cut apart one side, traced out all the pieces for right and left thigh sections and then glued the paper pep back together (so I still have a reference piece for how it all goes back together).
Here's the half I have traced out...
Now, I'm actually going to be a bit early tonight so I can (hopefully) be wide awake with the kids at 7am Saturday morning. :confused
Just a bit more work tonight...
I did some sanding on the hardened boot sole. I wish I could have primed it tonight, but apparently I don't have any more filler primer laying around.
So, I went ahead and installed the vertical support pieces in the heel. That should provide plenty of support, without adding the weight of a completely solid heel.
And here is the shoe test-fit... As stated before, my plan is to cast and pour two resin copies of the sole of the boot and then build a foam boot top around the slip-on shoes we picked up for $6.
*****
And I also finished up designing my paper pep templates for the thigh armor. I cut apart one side, traced out all the pieces for right and left thigh sections and then glued the paper pep back together (so I still have a reference piece for how it all goes back together).
Here's the half I have traced out...
Now, I'm actually going to be a bit early tonight so I can (hopefully) be wide awake with the kids at 7am Saturday morning. :confused
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Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/23
indy as always marvelous work,big thumbs up to your creativity:thumbsup
fingaz iron man mk4 wip
indy as always marvelous work,big thumbs up to your creativity:thumbsup
fingaz iron man mk4 wip
Scandvoice
Well-Known Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/23
As usual, I am in awe. Amazing work! ;-)
As usual, I am in awe. Amazing work! ;-)
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/23
Thanks, Fingaz and Scandvoice. You're encouragement is greatly appreciated!
Yep! I'm very happy that we made the duct tape dummy of Mikey. Mostly we created that for sizing the pieces without having to harass Mikey all the time, but the other benefit is that we have a place to pull the costume on display after he (and maybe his 3yr brother wears is).
I'm only trying to keep from thinking about how cool it would be to build a little Ironman suit-charger stand for it with lighting and all. That would make the display pretty awesome! lol
*****
So, I'm proud to say that I DIDN'T jinx myself this weekend. It was VERY productive!!!
Let's start with the coolest part I'm currently working on - the boots!
As you know, I've been working on an build concept that allows the sole of the boot to be hard enough to walk/stand on, and the top part flexible enough to provide comfortable walking.
To do this, I decided to build up a single boot sole and then (with the help of a good friend), cast and pour two resin copies of it. Then the slip-on shoe we bought would be attached to the resin base and the 'body' of the boot would be constructed in 3mm EVA foam (the same stuff I've been using for most of the suit).
Here is the fiberglass/bondo hardened sole, with the shoe sitting on top of it for sizing... also the 'body' of the boot that will cover the shoe is in the background.
So, we made a silicone cast of the boot sole in two parts. Here's what the first one looked like (as we were removing it from it's foam-board pouring box)...
And here is what both parts looked like...
My friend sent me a picture of the first pull, and I'll go pick up both boot soles tonight! Here's what the first pull looks like...
I just CAN'T wait to get Mikey's shoe mounted on this and the foam 'body' of the boot built-up so I can see him running around in them!:thumbsup
IF these work out well, it's possible that my friend and I might start an INT thread for full-size versions of these specifically for anyone building adult-sized Ironman/Warmachine suits out of foam.
*****
I've also been working this weekend on the last major foam parts (the thigh armor).
I had posted an image of the template pieces as I had them traced out on my foam, but here's how the first half of the thigh sections came out...
I then broke apart the other half of the paper pep template and traced out all the parts for the matching thigh pieces.
After cutting these all out, I built up one of these and attached it to the first half I had built... giving me one full thigh.
Here is how it looks (with a lower leg piece near it for reference).
So, that's what got done this weekend...
This is the last week of Sept, so I still feel like it will be close, but all this work makes me feel MUCH better about hitting our target of having everything done and ready at least a week before Halloween.
Thanks, Fingaz and Scandvoice. You're encouragement is greatly appreciated!
Yep! I'm very happy that we made the duct tape dummy of Mikey. Mostly we created that for sizing the pieces without having to harass Mikey all the time, but the other benefit is that we have a place to pull the costume on display after he (and maybe his 3yr brother wears is).
I'm only trying to keep from thinking about how cool it would be to build a little Ironman suit-charger stand for it with lighting and all. That would make the display pretty awesome! lol
*****
So, I'm proud to say that I DIDN'T jinx myself this weekend. It was VERY productive!!!
Let's start with the coolest part I'm currently working on - the boots!
As you know, I've been working on an build concept that allows the sole of the boot to be hard enough to walk/stand on, and the top part flexible enough to provide comfortable walking.
To do this, I decided to build up a single boot sole and then (with the help of a good friend), cast and pour two resin copies of it. Then the slip-on shoe we bought would be attached to the resin base and the 'body' of the boot would be constructed in 3mm EVA foam (the same stuff I've been using for most of the suit).
Here is the fiberglass/bondo hardened sole, with the shoe sitting on top of it for sizing... also the 'body' of the boot that will cover the shoe is in the background.
So, we made a silicone cast of the boot sole in two parts. Here's what the first one looked like (as we were removing it from it's foam-board pouring box)...
And here is what both parts looked like...
My friend sent me a picture of the first pull, and I'll go pick up both boot soles tonight! Here's what the first pull looks like...
I just CAN'T wait to get Mikey's shoe mounted on this and the foam 'body' of the boot built-up so I can see him running around in them!
:thumbsupIF these work out well, it's possible that my friend and I might start an INT thread for full-size versions of these specifically for anyone building adult-sized Ironman/Warmachine suits out of foam.
*****
I've also been working this weekend on the last major foam parts (the thigh armor).
I had posted an image of the template pieces as I had them traced out on my foam, but here's how the first half of the thigh sections came out...
I then broke apart the other half of the paper pep template and traced out all the parts for the matching thigh pieces.
After cutting these all out, I built up one of these and attached it to the first half I had built... giving me one full thigh.
Here is how it looks (with a lower leg piece near it for reference).
So, that's what got done this weekend...
This is the last week of Sept, so I still feel like it will be close, but all this work makes me feel MUCH better about hitting our target of having everything done and ready at least a week before Halloween.
jimbob1986
Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/26
Coming together very nicely. Really looking forward to seeing this finished.
Coming together very nicely. Really looking forward to seeing this finished.
Monster Dave
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/26
Hey, I'm a bit late to add my comments on this thread, but WOW! I sincerely hope that your son gets all he can out of it (enjoyment). What you're doing for him is outstanding!
It may not be possible for him to fully appreciate it now, but I bet he'll never forget it!!
Don't let it get destroyed after Halloween's over!! Keep it for when he's older and reflecting on how amazing it was!
Hey, I'm a bit late to add my comments on this thread, but WOW! I sincerely hope that your son gets all he can out of it (enjoyment). What you're doing for him is outstanding!
It may not be possible for him to fully appreciate it now, but I bet he'll never forget it!!
Don't let it get destroyed after Halloween's over!! Keep it for when he's older and reflecting on how amazing it was!
indiefilmgeek
Sr Member
Re: WIP Ironman Costume for 5yr old - Leg, boot & underarmor 9/26
Me too!:thumbsup
Thanks!
I've always said this project has been more than 50% my excuse to dive into materials and build methods I've never played with before. But, yes, I certainly hope it's a memory he can keep for years and years... or at least until we build him a fully-scale Voltron costume when he's 10. :behave
You'd be welcome anytime! Maybe a lab in Oak Ridge can hire you?
My local friends have all been asking me about what's next (after Halloween)... They all have been emailing me pictures of kick-butt costumes they'd love to co-build with me (I love my geeky friends!). And, while I have several projects in my sketch book right now that I'd LOVE to work on next; unfortunately, none of them are costumes. :confused
As much as I love building costumes, I also love inventing, designing and building all sorts of other stuff... so, I might need to burn through some non-costume projects before jumping back into another big costume project.
We'll see. :$
*****
Project update time!
Picked up the resin boot soles tonight - a HUGE 'thank you' to my friend (and a fellow RPFer) that helped cast and pour these!
I got them home and couldn't help but begin to sand them and get them smoothed down. They still seemed a bit heavy, so I also bored out the biggest part of the heel. We initially were going to cast this hollow, but it turned out too complicated to do that - so boring out some extra material seemed the next best thing!
When we create an adult version for sale (after Halloween), we've decided to make them out of a dense rubber rather than this inflexible resin. I think it will wear better and move a lot more comfortably.
Anyway, that's it for me tonight. Take care RPF - Nite All!:thumbsup
Me too!
:thumbsupThanks!
I've always said this project has been more than 50% my excuse to dive into materials and build methods I've never played with before. But, yes, I certainly hope it's a memory he can keep for years and years... or at least until we build him a fully-scale Voltron costume when he's 10. :behave
You'd be welcome anytime! Maybe a lab in Oak Ridge can hire you?
My local friends have all been asking me about what's next (after Halloween)... They all have been emailing me pictures of kick-butt costumes they'd love to co-build with me (I love my geeky friends!). And, while I have several projects in my sketch book right now that I'd LOVE to work on next; unfortunately, none of them are costumes. :confused
As much as I love building costumes, I also love inventing, designing and building all sorts of other stuff... so, I might need to burn through some non-costume projects before jumping back into another big costume project.
We'll see. :$
*****
Project update time!
Picked up the resin boot soles tonight - a HUGE 'thank you' to my friend (and a fellow RPFer) that helped cast and pour these!
I got them home and couldn't help but begin to sand them and get them smoothed down. They still seemed a bit heavy, so I also bored out the biggest part of the heel. We initially were going to cast this hollow, but it turned out too complicated to do that - so boring out some extra material seemed the next best thing!
When we create an adult version for sale (after Halloween), we've decided to make them out of a dense rubber rather than this inflexible resin. I think it will wear better and move a lot more comfortably.
Anyway, that's it for me tonight. Take care RPF - Nite All!
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