Ironman Mark VI - Foam - Australia - First time build

Coming along really well, I'm looking forward to seeing the paint job!
It's also great to hear about local places to source materials.
 
For the scaling tutorial you posted on this thread did you use the first method? Was it accurate? Did you have to start over for some pieces because of scaling issue? Did you also use the same scale for everyone of them? Nice build by the way (y)cool
 
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Sorry I've been neglecting you guys! I have been workin NONE STOP!

If you'd like to hear (read) the story continue reading, if not feel free to scroll down and check out the pics!

Tips and Hints
+ Try to have the suit painted days in advance so as to reduce the paint fumes.
+ If using velcro in the helmet, make sure the soft cotton side is facing your head.
+ Try to limit forward arm movement eg arms out in front, as this wears the widest parts of your chest piece.
+ Using sun glass lens as helmet eyes is a good idea. Googly eyes behind a mask are scary.
+ A red morph suit was warm and helped 'fill in' the blanks.
+ Make sure to have any mods needed done to the suit to enable you to go to the toilet. PLUS you will have a group of guys cheering you on when you go.
+ Figure out how to have some ventilation in your helmet, you're going to be wearing it a lot.
+ Wear a respirator went painting. Unless you want cancer.

*Summary*
It was Wednesday and I had to have the suit done by saturday.... uh oh
I still needed to finish the thighs, shins, boots, helmet, gloves and arc reactor. :S
I started taking my pep files into work to cut out during lunch breaks and when I got home I would spend the rest of the night building.
Finished the thighs, shins and helmet by friday and accepted that I was going to have give up on the boots and gloves if I wanted the rest to look good.
The paint I wanted was held in scarce proportion at only 1 store! (Super cheap Auto, Powerplus Paint - Velocity Red)
Unfortunately these cans also only came in 150g bottles at $13 each!!! I had to drive from Werribee to Thomastown to Syndenham to Sunshine and back. For those of you who do not know those places, that's about a 3hr+ trip.

Here are the paints I used
- 7x Black Plasi-dip (eBay)
- 2x Gold - Fiddly Bits (Bunnings Warehouse)
- 1x Aluminium - Fiddly Bits (Bunnings Warehouse)
- 7x Velocity Red - Power Plus (Supercheap auto)
- 2x Clear gloss - White Knight (Bunnings Warehouse)

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I spent all of Friday night and Saturday afternoon painting (I still had to work my full time job). I found that little sleep helped here....
Helmet paint job
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As I was about the spray the gold on the helmet the tube connecting the nozzle and can snapped!!! It was Saturday night and no way of getting more paint so I did my best to 'spray' (more like super drench/ fire hose drench, the helme in gold and used a paint brush to even out build up.)
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I was following this tutorial for the 'eyes'. Lighting Up The Eyes
I never got time to add the LEDs though.
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As for getting the helmet on and off, I opted for a very simple method. I just attache one side of the lower half of the (back of the) helmet and velcroed the other. One thing to take note of! Make sure the cotton side of the velcro is against your ear....
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Other stuff
Thighs
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Shins
I used the same method, for the hinges, as I did the elbows. About 3 layers of hard cardboard. This was fantastic as I spent about 8hrs walking around at Comic Con and NO sign of the joints giving way.
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After everything was painted (Saturday night) I realised the paint fumes were pretty bad. "I won't survive walking around in a helmet with all these fumes!" I thought. So I jumped on the net and looked at how to get rid of paint fumes. The most supported thing I could find was to put an onion cut in half near the painted objects and it will 'absorb' the fumes. I figured I'd put one in the helmet.. let's just say the helmet smelt of onion AND fumes. haha

Saturday night, midnight, no arc reactor!! I just cut out a printed arc reactor stencil and stuck a led lamp in the middle. Cheap, I know, but it was better than nothing.
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It was A LOT of time and effort put in but Sunday at Comic Con was amazing. NONE STOP photos and it made heaps of little kids (and big ones) really happy. I also won the Best Movie Costume Award.

Just want to say a BIG THANKS TO ALL OF YOU. You've helped encourage and support me all the way through. Thanks guys!

Ironman Vs. Zombies
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Ironman and Hulk (my mate) with MINI ironman and hulk!
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With my friends
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Winning the Cosplay comp!
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OH! I also can't forget to mention that I saw RJWilson and his costume looked flippin awesome! Great job mate!
 
Golgo: Thanks for the kind words mate. Pity you couldn't make it, Comic Con was PACKED. You'll probably see heaps of people raging because it was so full they stopped letting people in!

Mushroomhunter: Thanks man! The thigh was a little challenging, but for me personally I'd say the shins where the hardest. Nothing seemed to go right and I had to make a lot of modifications.

Thor: Thanks man! Yeah it's great seeing things you recognise, makes it cosier. haha

Nhat Phan: Yeah I used the first method. I altered the scaling on everything except the waist and helmet. Turned out pretty good.
 
Costume looks great man! Congrats on the cosplay win :D I read a lot of things about the Melbourne Comic Con being kind of ridiculously packed and under organised, sounds like it was true lol.
 
cheers man yours was amazing for how little time you had to build it. Congrats on winning best movie costume. I didnt even think to enter haha and you're right about non stop photos, from the time i got there till i left was full on.
 
Late to the party, but your suit looks great. Sucks you had to smell onions though :p also an Aussie from Brisbane.
 
Your build is inspiring.:cool

You are actually a true scratch builder, taking very basic plans and turning them into real world definitions of our beloved screen characters and taking the time to photo and list all of your material and outcomes so others can learn and appreciate.

Keep up the Great work!

RT
 
Paradox: Thanks man! It was so packed lol

Strickler: Thanks mate, the onion thing did suck haha but it was worth it!

despeerado: Thanks!

Rogue: Thank you for the kind words, they're greatly appreciated. I hope the posts have been able to help in some way, shape or form.
 
Some more things to take note of/tips
I joined the thighs to the COD using indiefilmgeeks velcro method http://www.therpf.com/f24/ironman-costume-5yr-old-links-page-1-a-113546/index21.html#post1964142

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One thing to note, if you are constantly taking the helmet off and on and moving your arms forward you may get some wear and tear (literally) on the edges of your chest. I'm not sure if this is due to incorrect scaling (though it didn't feel incorrect).
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After this experience I'm pretty keen to build a proper pepakura suit from fibreglass. I've never done this kind of thing but I'm going to start learning. I would love to one day have a suit that can have the helmet face plate open automatically, an authentic looking arc reactor. A suit that is durable and has good range of motion. :D

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Wow, this looks outstanding! It looks like you're in Melbourne, so I won't get to see it in person. I always attend Sydney conventions, just to check out all the amazing costumes.

Congratulations on the excellent work!
 
how about rondo ur build?? docholiday78 is doing an awesome build with his foam ironman
seems to be really durable.. as im starting, im not there actually, but ill try that way for sure
 
Ironhabs: That's a great suggestion, I'm looking into it and that will be what I do next!

Mushroom: Thanks mate!
 
Very impressive build! Couple of questions:

Can cardboard be used instead of foam?

What was the prize for the cosplay comp? :cool
 
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