Ironman Foam Build Recommended Foam sizes?

What ever you do (if you're thin/average in size) then keep your scale on all the parts exactly the same so it looks proportional and not goofy. It's a simple thing I learned from failing miserably on my first few suits. Just scale one piece and the rest should fit alright at that same scale.

I'm 6'3" and I kept the scale of the mark 6 suit at "26.000" and it fits perfectly.

Tj2N8.jpg
 
Last edited:
BL1TZKR13G said:
what do you use your cnc for? Picture framing? I have a Wizard Mat Cutter idk if i'd be able to use it to cut out the patterns....
Click to expand...

I have done some frames in the past but I do more large format sign work, 3D engraving, and industrial plastic forming and shaping. My claim to fame is the 16' tall hockey players in the closing ceremonies of the winter Olympics they were all cut on my CNC.
 
6mm is great for the helmet as long as you work your angles right and scale properly.
or else it'll end up like mine, all pumpkin-headed :( :p

10mm and 6mm for back and chest

6mm for arms and shoulders
3mm for hands, maybe some 6mm in there if you can work it.
shins, thighs, 10mm and 6mm. mostly 10mm
 
i used 5mm foam for my whole entire suit, it was plain and simple and less hassles with buying and cutting out different sizes and it worked really well for me... but yet again it all has to do with personal preference
 
Same advise it gave earlier. You need to bend the faceplate.
It is a two way bend (left-right curve and top-down curve).
If you have heat gun, oven or open flame, heat up the foam and press it to your knee.

Leave the small piece between eyes a bit longer and tuck in under the eyebrow. Or just add small piece of foam, and tuck it.
No need to make the cut under the eyes, makes it look like a crying/sad iron man

You need to get cleaner cut, I saw rough edges on faceplate top.
Yesterday, I build batman cowl and I use only scissor for 6mm foam.
Scissor for me give cleaner cut, easy to curve, and work okay with angle cut.

Of corse, check if you can fit your head, otherwise, you need to do something with the back-bottom part.

Apart from it, nice :thumbsup
 
IMIM2 Lol at the crying iron man, yeh i just went with the cuts the template had looking at it now i wouldnt have done the ones under the eyes. for alot of the cuts i used scissors for some i used a razor blade. Fits like a glove btw not really tight and not really loose probably shoulda scaled it 10% bigger. thanks for the constructive criticism it definitely could be cleaner.
 
I've been reading these threads for over a year and I finally got the guts to build my own suit. I'm building the mark6. After I folded the helmet, I used fiberglass strips to line the inside and then I use 2mm foam for the inside so it doesn't rub my face and then used different sizes on different pieces to give some areas more thickness. So with fiberglass giving the pieces their curve and using what I learned here, the foam to shape. I didn't make the bondo as thick so it wouldn't look bloated when I put it on. It's more steps then what you guys took but I'm not talented whatsoever and I didn't want fail and give up on my first try. I'm going big or going home.
 
I use 7mm foam for everything( helmet/chest/back/arms/abs/cod/legs/boots) 10mm is way to thick (in my experience)
Here's some pics of the Mk7 i built for a customer (below) just finishing a mk 6 at the moment
052.JPG056.JPG
 
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