Ironman Foam build...My first attempt at Pepakura

[Andyf430]

So I got into this sort of building in March, and since then I've had TONS of help from the pep files, tutorials, forums, and pics of numerous members on THERPF and for that, i thank you. Shout out to Stealth, robo3867, x-robotics, darkside, sharkman, dancin'fool and many many more. Here's my start...

 

[Andyf430]

So a little advice, DONT start with the helmet or chest! LOL I was so pumped to build, but i jumped the gun and as i got more practice at it, the arms and legs came out awesome, but then i realized my helmet looked like ****....so I rebuilt it with a diff set of patterns....it was scaled too small, so it became a helmet for my daughter....i painted it with my old costumes' paint ( macho man and scorpion) so it came out like the cartoon colors....

 

[Andyf430]

I also started a thread about my arc reactor entitled "EASIEST ARC REACTOR. PERIOD." I dont know how to link it in, so maybe someone can help me out...

 

[Scuba Bob]

Looks great! I'm doing my first Iron Man foam build this year as well. I would highly recommend checking out The Hero Tutorials - YouTube Stealth has some amazing advice on how to properly do these pieces.

 

[Andyf430]

i gave him a shout out in the first post...his vids are the reason i started mine..its great footage of the real process of this...Thanks again STEALTH

 

[Scuba Bob]

Haha sorry I apparently need to learn how to read lol. i missed the shoutout in the first post. Suit's looking awesome. i loved the arc reactor tutorial.

 

[Andyf430]

fyi the first pieces i made (helmet, chest) came out awful, because i was under the impression you can sand down the glue...false!

 

[Scuba Bob]

What ive been doing is using the tip of my gluegun or my soldering iron to run over the glue and melt it and then clean it off with a rag.

 

[Andyf430]

what works best is gluing the inside edge and putting the piece together from the outside in, so the glue smushes in, not out...

 

[Peejfro]

looks good man I just started myself not sure how to work the files so just went commando! done the abs section today, (easy bit first lol)

 

[Andyf430]

Nice! I actually combined a lot of files too...some small pieces can be taped together to make less seams out of foam

 

[Andyf430]

I need advice on hinging the calf to the thigh. I'm wondering if anyone on here added a piece to the inside of the shin? thoughts?

 

[Andyf430]

Here's my latest update...party is in a couple weeks, so i need to get crackin on details....I appreciate any advice

 

[Drack]

Looking nice bro. You will be the centre of attention at the party!

As for advice on the hinge I would love to give you some but I haven't got that far yet. I guess I will tackle it the same as I did for my arms. I cut a 3mm trough on the inside of the bicep and forearm then glued into them some 3mm PVC reinforcements which I drilled for the bolts to go through.
I will take some pics in a bit and hit you up with them. Did you hinge your arms btw?

Tom.

 

[Crisgo]

Wow you did a stellar job my friend. So the entire build is out of foam including the helmet? I look forward to my first attempt at Pepakura in the next few weeks.

 

[Andyf430]

thanks! Yeah the build is all foam. I used 3-4 coats of 70%-30% Mod-Podge LIQUID (not spray) and water, 2-3 coats of filler primer, 2-3 coats of Toreador red Dupli-color from auto zone and 2-3 clearcoat ENAMEL gloss. As for the hinges, I cut out plastic washers out of the lid of an old Rubbermaid container and used those "chicago-screws" AKA threaded post connectors to make reinforced contact points at the elbows and the knees. Inside the legs, i added a a large plastic reinforcement lip to support the hinge. I'll have More pics on the way. Good luck!

 

[Andyf430]

I finished the suit with the led flashlight circut board in the plams, and bought a gold Sharpie Paint pen for all of the gold accents....it worked awesome!

 

[Andyf430]

I am only 5'8" and i had to shorten the legs by cutting off a 1/2 inch, leaving very little room for hip pods...the space in between the cod and hip isnt round, more of a small football shape. any thoughts? hip pod attatched to the leg? leave it off?

 

[sniggle]

Thanks for the tip concerning the arc reactor!
I went and bought the same sink strainer from Home Depot and made one as well. :]

A couple of questions:

I noticed that the strainer fits perfectly into the chest, but the metal frame on the top of the strainer makes it sit on top, instead of further into the chest.
Did you alter that piece in anyway?
[If you take a glance at the pic in my thread, you might see what I mean.]

Got any tips on repulsor lights in the hands?
They look great :]

 

[The Mighty Gray]

Good work man!! Keep at it!

Check out my First Build!