markcra
New Member
First off, I need to give a massive thanks to theRPF and specifically robo3687, Sharkhead7854 and JFcustom, the latter for their collective work on the Iron Man suit/helmet pepakura files and for sharing them. The former for all the inspiration and insights (so many hours spent perusing threads). I've been lurking for over a year now and figured as a means to push myself I'd start posting progress (or lack thereof).
Back Story
I started my costume about this time last year, having found JFcustom's thread, by buying a lot of yoga mats out of Decathlon. I decided to shortcut transferring the patterns to foam via paper and instead laser cut and etched the foam at my local makerspace (at the time I was volunteering there, I now work there full time). I balanced the settings on the laser cutter so the cuts didn't go all the way through and etching only affected the surface. This kept pieces together for taking home and made identifying groups of parts far easier. I started from the top and worked my way down, completing the helmet first followed by chest plate (and a laser cut arc reactor), back, shoulders and only one bicep before putting everything away for the best part of a year.
On a mannequin
"Honey, where is my super suit?"
My first attempt at the Arc Reactor
Arc Reactor Selfie
Present Day
Early September I dusted the pieces off and started work on progressing the armour. This weekend I decided a mannequin was needed, up until now I haven't dwelled on how the foam pieces will be worn and I couldn't visualise them on myself. I found video walk-throughs on YouTube describing how to make a mannequin using duct tape and old clothes. A trip to B&Q for supplies, 3 rolls of duct tape and some disposable overalls, and I somehow persuaded my wife to tape me up. I'm now making a frame to stand the mannequin on and stuffing it with bubblewrap and paper.
Back Story
I started my costume about this time last year, having found JFcustom's thread, by buying a lot of yoga mats out of Decathlon. I decided to shortcut transferring the patterns to foam via paper and instead laser cut and etched the foam at my local makerspace (at the time I was volunteering there, I now work there full time). I balanced the settings on the laser cutter so the cuts didn't go all the way through and etching only affected the surface. This kept pieces together for taking home and made identifying groups of parts far easier. I started from the top and worked my way down, completing the helmet first followed by chest plate (and a laser cut arc reactor), back, shoulders and only one bicep before putting everything away for the best part of a year.
On a mannequin
"Honey, where is my super suit?"
My first attempt at the Arc Reactor
Arc Reactor Selfie
Present Day
Early September I dusted the pieces off and started work on progressing the armour. This weekend I decided a mannequin was needed, up until now I haven't dwelled on how the foam pieces will be worn and I couldn't visualise them on myself. I found video walk-throughs on YouTube describing how to make a mannequin using duct tape and old clothes. A trip to B&Q for supplies, 3 rolls of duct tape and some disposable overalls, and I somehow persuaded my wife to tape me up. I'm now making a frame to stand the mannequin on and stuffing it with bubblewrap and paper.
Last edited:
