Sandbagger's Iron-Man builds - Now in STEEL

[PukkaLemons]

My man you Sir are an engineer! And an inspiration. And that suit is a work of art. Wish you well.

 

[sandbagger]

^^^ Thanks guys.

In yet another attempt to solve the inflexible gauntlets problem, I am revisiting the EVA foam option, this time using contact adhesive to wrap it in metallic stretch fabric.


I'm employing a few techniques from the steel trial I did a while back which makes the fingers much more form-fitting and even, plus leaving a little bit of foam to connect each piece at the side of each join.


I'm thinking of making the top knuckle joints out of ice-cream container plastic. It's rigid, it will fold with a sharp line and it is still flexible.


Looks pretty promising so far, comfy as heck and offers me FULL range of motion.

 

[joberg]

The inside of that helmet looks more and more like a Vader reveal way too cool!

 

[sandbagger]

Ta mate.

Micro switch for the lights wired up and working. Just got to fix it into the helmet slot now. Switch activates when the faceplate closes all the way.

 

[sandbagger]

Placing a microswitch in the power line for the eye lights, the faceplate presses down on it when it closes. All that's left on the lights is to hook up the dimmer switch that is already installed under the chin and put in a resistor for indoor/outdoor brightness settings.

 

[sandbagger]

EVA foam gloves wrapped in metallic lycra. Seems to be working well. Thumb has full movement and the soft option will be a lot safer for the hospital kids.


The trick to this is to make sure that both surfaces are painted evenly with contact adhesive and that it is almost dry before bringing the surfaces together. Detail is surprisingly good.


Four fingers to make and wrap to get this hand done, then install lighting in the central PVC ring.

 

[George]

Looks great and solved another lingering problem :thumbsup
Well done,SB

 

[sandbagger]

Looks great and solved another lingering problem :thumbsup
Well done,SB

Thanks George.

Adding technical details after seeing Leylander's post on the other thread. Thanks Leylander!.


1 mm aluminium sheet, cut and shaped, then I used the end of a bolt to bash the details into the surface, followed by a nail punch in the centre. Buffed to a high-polish and contact adhesive to fix in the grooves.

I'm making the next glove slightly different. Instead of all the pepakura unfold patterns creating a lot of seams and glue-lines, I cut the glove in half, flattened it out then traced it onto fresh 2mm foam. The glove is now one-piece with the details glued on the outside, then wrapped in metallic lycra.

 

[sandbagger]

Both palms done. Onto fingers next.

 

[ShaunDark80]

I'm liking this method - I'll probably stick with my gloves, but this could be good for the undersuit details around the upper leg/butt............

 

[sandbagger]

I'm liking this method - I'll probably stick with my gloves, but this could be good for the undersuit details around the upper leg/butt............

yes I think this stuff is absolutely ideal to cover the gaps so many seem to omit.

 

[sandbagger]

I've been working on the hands for a few days now. Still not quite done on them, but this guy is starting to look pretty menacing with extra digits now!

 

[George]

Awesome as always :cool

 

[sandbagger]

Thanks GM.

 

[Leylander]

Looks comfy. I think the method I am going to use provides the same movement.

This looks ace though

 

[sandbagger]

Gauntlet design explained.

In order to keep all the finger pieces aligned and together while allowing for bend, I have left some of the foam material in the joint, rather than cut them apart. A quick reinforce with the stretch lycra and contact adhesive before wrapping it all up in the same lycra.

 

[sandbagger]

FINALLY!!!

 

[sandbagger]

 

[horus]

This is great work, I started with pepakura but my fingers are clumsy and I squashed it as I glued, inspired to have another go now I have seen your efforts, your metal version looks even better !

thanks for sharing the photos.

 

[JayCVenlo]

Really great idea for cosplay version. But hopefully you still got the steel version for display purposes?

http://www.youtube.com/watch?v=Xj7wbiUF98E