Ironman foam first ever build!! COMPLETED!!

[Helagak]

Hi all! First time ever building something like this. I've started my ironman (mk IV/VI) I've mostly completed the foam/glue part part of the helmet. (why did I START with the hardest part?!?!) anyway, my first problem is, I can't get my fat head thru the neck hole!! I was thinking about finishing it, PVA glueing it and plasticoting it them cutting out a flap from the back that will be on a hinge with a closure so I can get my head in, then closing it. Has anyone come up with a more elegant solution? I can be the only one with a fat head....
Thanks for any ideas!
And for the (very rough!) debut!!:

Still lots of work to do, but it's taking shape!!

*edit* thought I would add an "after shot" to go with my first picture of that pathetic helmet. I (with is still sitting on my shelf of shame Btw!

 

[Kevin Gossett]

Re: Ironman fom first ever build. Ideas welcome!!

Cutting the back of the neck off and then reattaching with magnets is the typical solution

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Magnets!! Not that's a heck of an idea!! Thanks.

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Magnets!!! (argh!)
So I got some rare earth magnets. I slit open the back, and cut out divers for the magnets to reside in. I put two sets in. So it comes together and closes nicely. But the hot glue can't hold them! No matter what I do, they pull out of the glue. I tried putting a thin coat over them so they were completely enclosed in the glue, but found they wouldn't pull the pieces together nicely. so I kept shaving off layers untill the tops o the magnets were completely clean. Closed perfect! But then the magnets popped out! >_<.
Would someone mind showing me how they did thers?
Thanks alot.

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

I'm ready to throw this thing away and stick with my old hobby: drinking!
I honestly don't know if it's worth going any further... Ugh... Anyways, here it is. I have the face plate just tacked on to hold the shape till after the PVA is applied. Then hopefully i can cut it off and the face plate will still fit. This thing is like a puzz-3D for sadists!! Haha.

 

[teragon]

Re: Ironman fom first ever build. Ideas welcome!!

don't give up man, nobody said it was easy, it takes time, patience and a lot of tries and mistakes to get thing rights.
I did 4 forearms, and still not happy with any of them ! If it gets on your nerves, move to another piece, you'll get back to the helmet later !
Can't help about the magnets, but for the faceplate to keep its shape you indeed need to coat the full helmet with whatever you're planning to use, then cut the plate off, it's the way to go. If you're looking for an easier piece, to get some experience et get confortable with foam, try the shoulders !
By the way, can't see the last pics, seems like the code is missing something...

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Thanks for the encouragement. We shall see.
Pics fixed.

 

[teragon]

Re: Ironman fom first ever build. Ideas welcome!!

Well, this is quite good actually, no reason to throw it unless you are not happy with it, but to me it just needs some cleaning and you're good to go :thumbsup I simply use my hobby knife to cut the glue oozing out the seams, quick easy and clean.
Giving the type of foam you're using, you could also use a heat gun to curve your foam into the shape you want, if you don't do it already, that way it will keep its shape pretty well ! But don't heat it after you glued your parts together, trust me I made the mistake : the glue melts and things get nasty...

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

I decided to cover it in glue and see what happens.
First coat mixed about 1:1 (too runny!)

Second coat paired in straight (MUUUCH better!)

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

My main issue with it is the fact that I did a terrible job cutting the foam! Beginners....errr UNluck?? Haha so I used hot glue to fill some of the gaps. Then the mask totally didn't fit. I ended up cutting the jaw off, cutting a pie slice out and re attaching it.
I am going to keep going since this isn't actually going to be an "iron man" as much as an "iron beer man". instead of paint, I'm going to cover it in beer boxes. So hopefully, I can cover most of my mistakes. I am going to use this as practice for my real ironman suit. Thanks for the advice, teragon!!

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Small update. Here she is after two coats of PVA. O e or two more than I'll decide if I am going to plasticote it. Or just gO straight to skinning it.

I started on the chest piece last night. I used 12mm fatigue floor mats. And I got one of those "hot knife" soldering irons or whatever, hoping that would help with my cuts. I also to alot more time cutting out my templates. But the hot knife seemed to make uglier cuts than a straight exacto! SHM... Anyways, pics of the chest when I get some more done.

 

[lokey69666]

Re: Ironman fom first ever build. Ideas welcome!!

Keep to it man.
I am having the same issues all across the board.
Try using some car bumper primer on the foam as well, it has a bit of flex in the paint and you can cover it with almost anything.

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Tha is Loki. That's a good idea.
Btw, your sig... So there are 3 types of people?? I generally see it written as "10 types of people". But more accurately, it should say "01 types of people".

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Well, I have officially decided to use this elmer as my "beerman" helmet. I am going to try to start a new helmet for my actual iron man build. Here it is after I started "skinning" it:

I also started ony chest piece. I used different foam. These are 1/2" anti fatigue mats. Kind of hard to work with, but I am starting to get a feel for it.

I am going to order some 3mm foam off wandys to do the new helmet when I get around to that. But I think I am going to keep working on the armor to get more practice before I tackle a new helmet.

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Oh, and a small tip I figured out! The cardboard that beer boxes are made of (for cans, not bottles) can be shaped similar to foam. Take a heat gun to it and you can get compound curves. Not as well as foam does, mind you, but it does work to an extent.

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

Not so much an "update" but I have a problem...

Stark industries is beig overrun by KITTENS!!!
Wat do???

 

[teragon]

Re: Ironman fom first ever build. Ideas welcome!!

Make them a suit too ^^ ? for what would you use cardboard exactly ? I mean do you use it over the foam or instead of foam ? Isn't it a bit thin ?

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

I decided to make my first helmet attempt a "beer man" helmet. So instead of paint, I started "skinning" it with beer boxes. (see pic in previous post)
I only mentioned the cardboard because I have seen people using cardboard in other builds. (like the cardboard robo cop or the $10 (gbd or whatever) storm trooper helmet) just thought the heat gun trick might be useful to anyone trying to achieve complex curves with cardboard. Not useful f most people doing Foam builds, but who knows!
I am going to rebuild my helmet after I complete the suit. So I have more experience and (hopefully!) better skills. It has become clear that my first helmet is almost unusable. :-/ when I cut as adjusted the jaw piece, it hanged the hole geometry of the helmet and now I cant see out of it!! >_<
Anyways, I'll keep chugging along and trying to learn from my mistakes!
*edit* love your "iron kitteh" idea!! Haha

 

[Pyrotechx]

Re: Ironman fom first ever build. Ideas welcome!!

Make them a suit too ^^ ? for what would you use cardboard exactly ? I mean do you use it over the foam or instead of foam ? Isn't it a bit thin ?

I am guessing he is using it for "test" pieces. I plan on doing the same thing actually, but using cereal boxes. I want to print out the templates on card stock then outline it on the cardboard cereal box and try to create a mock up of the helmet that would be made out of foam, this is to mainly test fit it to my head.

 

[Helagak]

Re: Ironman fom first ever build. Ideas welcome!!

That's a really good idea pyro. Just remember, depending on the thickness of the foam you use, it will change the size. Eg; thicker foam will make the helm "smaller".