slightly stuck with materials for my Iron Man Mark III cosplay - advise?

[Sarnelia]

Ages ago I started building a pepakura Iron Man Mark III helmet, got stuck, started again with another model, started a chest piece, got stuck again. My main concern is and has always been health safety while building these things (as I'm a complete lay when it comes to working with hazardous material), which in the end made me settle for Jesmonite (Aqua based resin), no glass fibre at all (not even cloth, even though the chest piece does have some in it from when I tried), just some lame, normal filler and then primer. That's as far as I got. I gave up on filling and coating and sanding and shaping the chest piece yesterday and finally applied some primer, though I'm not yet convinced whether I should leave it at that and put the lacquer on top, or whether it's worthwhile doing some more minor corrections with filler. Overall, I'm fairly pleased with the result so far, though, even though it's far from perfect.



BUT: I'm feeling really insecure about the whole sanding and Jesmonite and everything, so would best like to avoid it. Also, the whole pepakura thing is technically absolutely awesome, but if I continue in that speed, it'll take me another 10 years to finish the suit, if at all. I was now therefore trying to think up alternatives, and came up with the idea of possibly purchasing some cheap, plastic motorcycle body armour (especially for the back) and then trying to adjust that accordingly (and somehow attaching the chest piece, because that was a lot of work and I definitely want to use it). So, has anyone here ever done something like this? Or has anyone any ideas to what kind of material I could use to adjust an armor thing like that? Foam maybe and a lot of glue? Or is that a complete rubbish idea? I know it won't ever be as nice as if I'd build the whole thing properly from scratch and used fibreglass resin, but... ?

Would appreciate your thoughts massively!

 

[Vox]

I'm curious about what it is that has you so nervous about working with hazardous materials. Unless you are sanding without the proper respiratory and eye protection, you should not have a whole lot to worry about. Are you extremely allergic, and therefore nervous about skin contact?

 

[Sarnelia]

Hi, thanks for the reply!

I think it's mostly that I don't trust myself to not miss something since I have literally no idea about what I'm doing and no garage or good place to actually work in. I have to either do it in the garden while it's semi-nice (living in the UK doesn't help) or in the kitchen, both not ideal. And I'm just a little afraid that I might be doing something wrong as in that the mask has the wrong filters in or it's not actually properly closed etc. etc. It just freaks me out a bit. I've seen some tutorials with people telling you what you need to get to work with certain materials, but if these things just come from some random people on the internet, there's always a bit of uncertainty left. I know that sounds a bit odd, but I'm doing this for fun, so if possible I want to avoid all unnecessary risks, if that makes sense.

 

[IronMeg]

I started with fibre-glass and found that is was NOT for me. I don't have the patience or the sanding ability for it at all. I admire the people that can do it, but that isn't me. I adore working with foam though. Have you looked into the foam suit builds? It can be done inside (except for painting) with wood glue and a hot glue gun.

 

[sandbagger]

Mate, I understand your concerns and environmental limitations perfectly well. It sounds like the quietest, least smelly, dust-free and easy option for you is foam building with a sharp exacto knife and a cheap hot-glue gun. It's quick and can look very good. The more you do it the cleaner your cuts and joins will get. Don't expect your first build to be your best or even your last, as you will get hooked for all the right reasons. mainly because it's FUN!!!

You can get away with cheap hot glue guns (7$) and packs of hot-glue sticks, ($2.50) but if you spend a little more money on a quality gun and sticks, the joining will be all the better for it.

https://www.google.com.au/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-8#q=hot glue gun

Go to a craft store or a sewing shop and get yourself one of those green plastic cutting mats. They will save your blades tremendously.

http://www.officeworks.com.au/shop/officeworks/c/office-supplies/stationery/cutting/cutting-mats

keep your knife SHARP SHARP SHARP! At all times. Either lots of spare blades, changing often, or get one of those v-sharpeners to regularly run your blade through. It makes MASSIVE difference to your cuts.

http://www.ebay.com/itm/Black-2-in-...rs-V-Sharpener-Tungsten-Carbide-/261572939220

Check out JF Custom's foam files. I know he had done great work modifying ROBO3687's files for foam. He has a BRILLIANT thread here which is absolutely paramount to read!

http://www.therpf.com/showthread.php?t=148889

I hope this helps mate.

SB

 

[Sarnelia]

Thanks A LOT! I was thinking today that maybe foam might be worth looking into after all and I think you convinced me. Sounds like it's definitely worth trying, so thanks!

 

[sandbagger]

Thanks A LOT! I was thinking today that maybe foam might be worth looking into after all and I think you convinced me. Sounds like it's definitely worth trying, so thanks!

My pleasure. Good luck and make sure you post your progress. Failures as well as successes are so good to see here so we can ALL learn from them. If you make mistakes, SHOW US! We can help solve challenges and your mistakes could save someone else from falling into the same traps.

SB

 

[Ikras]

Foam can give some really nice results and when finished well it wont be clear that's what it started life as either. JF Custom's thread was one of the first places I started as well and the information there is great.

My pleasure. Good luck and make sure you post your progress. Failures as well as successes are so good to see here so we can ALL learn from them. If you make mistakes, SHOW US! We can help solve challenges and your mistakes could save someone else from falling into the same traps.

SB

I agree entirely with sandbagger here. As with anything there will be times that things don't go to plan or something doesn't seem right and chances are someone here will have experienced it as well or will have an idea or suggestions on where to go next. People are happy to help.


Just want to say thanks as well to sandbagger for that sharpener link. Seems to be one I can finally track down in the UK. Been on the lookout for a while, I can finally start to save my blades now.

 

[sandbagger]

Foam can give some really nice results and when finished well it wont be clear that's what it started life as either. JF Custom's thread was one of the first places I started as well and the information there is great.



I agree entirely with sandbagger here. As with anything there will be times that things don't go to plan or something doesn't seem right and chances are someone here will have experienced it as well or will have an idea or suggestions on where to go next. People are happy to help.


Just want to say thanks as well to sandbagger for that sharpener link. Seems to be one I can finally track down in the UK. Been on the lookout for a while, I can finally start to save my blades now.

No Probs. Just google image search V sharpeners and you will see many variants.

SB