STEEL IRONMAN - heavy update - NEW PHOTOS PAGES 3,4,6
- Thread starter samurai169
- Start date
samurai169
Active Member
Re: STEEL IROMAN - heavy update
So lastknight to answer your question as to how I've obtained suck a smooth and clean. I've done this for the most part without having to do major forming work. The pep style files work very well. So long as you can weld. The pep files remove the need for major forming. After grinding down all the edges I then use a sand paper style disk attached to my drill to further smooth all surfaces. After everything is smoothed out I use a bondo style Kevlar fiberglass reinforcing product which is the final top surface. Also I have been making steel armour and restoring period armour for over twenty years so I have picked up some tricks. PM me if you think I can be help lastknight or anyone else for that matter I will help if I can. I'm going to try to post some updates tomorrow. I've been busy. My legs are almost finished I'm about to start a new chest plate and forearms as well as finishing the cod that I've started on already and my flexible abs idea. I've purchased several electronics items from therealtonystark which should be great additions. Also thanks dagibbon.
So lastknight to answer your question as to how I've obtained suck a smooth and clean. I've done this for the most part without having to do major forming work. The pep style files work very well. So long as you can weld. The pep files remove the need for major forming. After grinding down all the edges I then use a sand paper style disk attached to my drill to further smooth all surfaces. After everything is smoothed out I use a bondo style Kevlar fiberglass reinforcing product which is the final top surface. Also I have been making steel armour and restoring period armour for over twenty years so I have picked up some tricks. PM me if you think I can be help lastknight or anyone else for that matter I will help if I can. I'm going to try to post some updates tomorrow. I've been busy. My legs are almost finished I'm about to start a new chest plate and forearms as well as finishing the cod that I've started on already and my flexible abs idea. I've purchased several electronics items from therealtonystark which should be great additions. Also thanks dagibbon.
samurai169
Active Member
Re: STEEL IROMAN - heavy update
Sorry lastknight I forgot to answer one of your questions. As to how long I've. Been working on my suit. Each major section has taken one day to cut and weld everything together, another day to grind and sand everything. And another day for the Kevlar fiberglass reinforcement layer and final sanding. As for paint each piece has a minimum of 4 coats with different grad of sandpaper in between each coat (finer grades progressively) the final coat gets sanded with 3000 grit wet paper for a baby butter smooth finish. I've been working on and off basically for a few months now.
Sorry lastknight I forgot to answer one of your questions. As to how long I've. Been working on my suit. Each major section has taken one day to cut and weld everything together, another day to grind and sand everything. And another day for the Kevlar fiberglass reinforcement layer and final sanding. As for paint each piece has a minimum of 4 coats with different grad of sandpaper in between each coat (finer grades progressively) the final coat gets sanded with 3000 grit wet paper for a baby butter smooth finish. I've been working on and off basically for a few months now.
LastKNIGHT
New Member
Re: STEEL IROMAN - heavy update
You say you only took a day to cut and weld everything together... Yet I've been failing to shape even half of the helmet for well over a week
If it's still possible, I'd like to take a look at your original patterns. If there's a digital copy of your patterns, that'd be amazing.
You say you only took a day to cut and weld everything together... Yet I've been failing to shape even half of the helmet for well over a week
If it's still possible, I'd like to take a look at your original patterns. If there's a digital copy of your patterns, that'd be amazing.
samurai169
Active Member
Re: STEEL IROMAN - heavy update
Pm sent lastknight. Once I'm finished with all my welding I will try to locate my helmet pattern for you.
Thanks torx I have a bunch of updates to post I just need to find some time. I might post a large update tonight or tomorrow for everyone. Most of the build is finished now. Just a few pieces left to complete. After Halloween I want to redesign the entire back to add more details to it and finally start on the full steel boots.
Pm sent lastknight. Once I'm finished with all my welding I will try to locate my helmet pattern for you.
Thanks torx I have a bunch of updates to post I just need to find some time. I might post a large update tonight or tomorrow for everyone. Most of the build is finished now. Just a few pieces left to complete. After Halloween I want to redesign the entire back to add more details to it and finally start on the full steel boots.
samurai169
Active Member
Re: STEEL IROMAN - heavy update
Ok sorry for the delay I've been very busy lately. So here is some update photos. The cod section is started almost finished, the legs are almost complete, started a new chest and back pattern the cod, back & chest are all free hand drawn and designed to be more movie accurate. The new back is hot off the welding bench and hasn't been ground smooth yet, but will be tomorrow. I'm hoping that by the end of this week to have all welding completed so I can more on to the final finishing of all parts.
Ok sorry for the delay I've been very busy lately. So here is some update photos. The cod section is started almost finished, the legs are almost complete, started a new chest and back pattern the cod, back & chest are all free hand drawn and designed to be more movie accurate. The new back is hot off the welding bench and hasn't been ground smooth yet, but will be tomorrow. I'm hoping that by the end of this week to have all welding completed so I can more on to the final finishing of all parts.
Ruprekt
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
This is an extremely cool project! Makes cutting up foam look easy by comparison. As for working with aluminum, (that's what I do for a living) it would be much easier to work with and much lighter and easier to form. However, welding aluminum is a tricky thing to say the least. When heated via welding, aluminum moves all over the place. To do something like this you'd have to control the heat by using a tig welder. Like anything else, it just takes practice. Looking forward to more pictures as your project progresses.
This is an extremely cool project! Makes cutting up foam look easy by comparison. As for working with aluminum, (that's what I do for a living) it would be much easier to work with and much lighter and easier to form. However, welding aluminum is a tricky thing to say the least. When heated via welding, aluminum moves all over the place. To do something like this you'd have to control the heat by using a tig welder. Like anything else, it just takes practice. Looking forward to more pictures as your project progresses.
samurai169
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
If I can figure out how I will add it on an upgrade. : )
If I can figure out how I will add it on an upgrade. : )
samurai169
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
Very cool now if only I had Tony Starks money to buy them.
Very cool now if only I had Tony Starks money to buy them.
Last edited:
pitufovengador
New Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
Awesome project! Keep up the good work
Awesome project! Keep up the good work
samurai169
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
The closest that anyone related to marvel has come to seeing my build is Stan Lee when I got him to sign my chest plate at fan expo. Unfortunately my suit wasn't done in time for the expo so the only piece I had was the chest. He was very impressed by it and was unable to hold up the chest piece while signing it. One of the security people had to assist with that. There were a few special effects people that I met that could not believe the quality and finish of my chest plate. This has been a tough build so far I sooooo can't wait till its all finished and I can start to tweak little details here and there. Right now I'm waiting on some electronics from therealtonystark for my suit just to jack up the overall realism of my build. After Halloween I plan on possibly making new arms and starting on the boots. I don't think I'm going to have enough time to get a final design drawn up and build them before Halloween. I also have plans to design a couple of new helmets so I can choose what I feel like wearing.
The closest that anyone related to marvel has come to seeing my build is Stan Lee when I got him to sign my chest plate at fan expo. Unfortunately my suit wasn't done in time for the expo so the only piece I had was the chest. He was very impressed by it and was unable to hold up the chest piece while signing it. One of the security people had to assist with that. There were a few special effects people that I met that could not believe the quality and finish of my chest plate. This has been a tough build so far I sooooo can't wait till its all finished and I can start to tweak little details here and there. Right now I'm waiting on some electronics from therealtonystark for my suit just to jack up the overall realism of my build. After Halloween I plan on possibly making new arms and starting on the boots. I don't think I'm going to have enough time to get a final design drawn up and build them before Halloween. I also have plans to design a couple of new helmets so I can choose what I feel like wearing.
LastKNIGHT
New Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
Looking real good!
Looking real good!
samurai169
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
Thanks lastknight. The new back is looking great. I ran out of steel before I posted that picture. The back is almost complete now. I'm holding off till the new chest is finished so I can properly align the sides I've also managed to add the spinal column details and the side plating details. I will post some new photos in a couple of days.
Thanks lastknight. The new back is looking great. I ran out of steel before I posted that picture. The back is almost complete now. I'm holding off till the new chest is finished so I can properly align the sides I've also managed to add the spinal column details and the side plating details. I will post some new photos in a couple of days.
samurai169
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
Just finishing the new chest plate and back plate. My electronics arrived today from the realtonystark. They should be getting installed in the next couple of days. I will post some updates in a few days.
Just finishing the new chest plate and back plate. My electronics arrived today from the realtonystark. They should be getting installed in the next couple of days. I will post some updates in a few days.
samurai169
Active Member
Re: STEEL IROMAN - heavy update - NEW PHOTOS PAGE #3
Ok so here"s some progress photos for everyone... the build is essentially finished now on to kevlar coating everything finishing off the electronics from the realtonystark which are amazing I might add I highly recommend his stuff, and all the final detail pieces.
Ok so here"s some progress photos for everyone... the build is essentially finished now on to kevlar coating everything finishing off the electronics from the realtonystark which are amazing I might add I highly recommend his stuff, and all the final detail pieces.
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