The Perfectionists Ironman Mark VII - Large Update on Page 2 (OCT28)

[Michael Wessels]

Re: The Perfectionists Ironman Mark VI

Need help from you. I have some problems with the scale on pepakura, i think im as tall as you are, please tell me how tall are you and which scale did you use on pepakura scale.
Thansk.

I wish I could help, but scaling is not my expertise at all. I am currently staying at a friends house due to work and don't have access to my usual tools. I am unfamiliar with their printer/its settings and this is technically my first pep build, as the only thing I have done before this was the tester helm(which I thought was the actual helm till I was done then realized it had very little detail).

There are however a bunch of threads on scaling that I have come across on my perusing of this site. I think the best way to do it would be to do the tester helm which can be built in 5-10 hours and see how you would scale that, then scale the actual helm accordingly.

 

[spydrwebz]

Re: The Perfectionists Ironman Mark VI

This build looks VERY nice!

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VI

Here is an update for you guys. The second attempt is coming along really well with very minor problems. Only around 4 or 5 tabs are a little off, but you can't tell from the shape, so far as I can tell. I should be able to finish it up today.

I am also working on a way of finishing the helmet (the coating to make it hard) that doesn't involve chemicals and fiberglass, as I am staying at friends for an extended period and don't have access to a place with ventilation.

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VI

So as promised, I finally finished the pepping. The last joint took about 1.5 hours to do haha, and a couple of curses. I am pretty happy with it, and I think I can adjust the pieces to fit slightly better than they are, a bit of overlap here and there. But I am happy!

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VI

So I am changing thing up a bit. Apparently I did not know exactly which ironman suit is which, because I actually like the VII more than the VI. So that is where I am headed. I don't think it will be to hard to modify the helm/ make a new one someday.

But I am starting on the rest of the body's pepping today. Printing out the chest right now. I unfortunately don't know how to scale so I will have to probably make a couple pieces over. I can't find the way to measure parts in the pep viewer, to match it with my measurements.

Oh well. I am also sealing up the helmet right now, using a spray on paint primer and then I will be attempting to use a non chemical based way of hardening it. Will let you know how it works!

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VI

Here is a funny and frustrating update for you guys. The people I am staying with had people over last night, so I stayed at another friends. I sleep in their basement and have a room to myself. I always close the door as my ironman stuff sits on the floor in the corner.

Someone went into my room last night and left the door ajar, but didn't hurt anything. The family dogs however didn't like the smell of my helmet, so one of them peed on it....
Fortunately, I just finished sealing it from moisture with several layers of paint primer, so I wiped off the pee an set it in the sun. Good as new. Nearly had a heart attack though, as they chewed up a failed piece.

Starting PVA coating today!

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VII

So here it is after 2 layers of PVA. Very little to no warping occurred during application of the layers. Very happy with where it is at the moment.

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VII

Hey everyone. It has been a while since I updated. I have been travelling and the helmet is slow going.

I set out to build it completely without using any resin based products that would require all the safety equipment and ventilation, as I dont have access to any. So everything I use so far is water based and can be done in a basement or bedroom. anywhere. Here are the pics.

I decided to use a cloth rags to give it some fibrous strength, so I cut them into about 3x3inch squares and used white glue to glue them on the inside.

Next came the hard part.What to use instead of Bondo. Thankfully my father knew of something he used to use which works well. It is called Foam Coat and is made by Rosco. It is used to cover styrofoam and such for buildings. It looks kinda like a liquid icing and can be applied easily. It is also waterproof once dry, and can be sanded quite smooth.

Now the trick to foam coat, is that is dries very very hard, making it a pain to sand. So i developed a system. I applied the foamcoat evenly, trying to get it smooth and thin as can be. Then let it sit between 1hr and 2hrs depending on the thickness. I then used a wet paint brush to brush the semi dry foamcoat, smoothing ridges further. after about 5-6 hours you can sand it carefully, and after 24 hours it is rock solid and you can really go at it with a 100 grit sandpaper.

Here is where it stands now. I had to build up the side, as they sunk in slightly when I PVA'd it. I am on my second layer. Sanding with a piece of 100grit sandpaper glued to a paint stir stick.

 

[Hastings]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

This looks amazing! Do you find that the FoamCoat makes it heavier than fiberglass would?

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

This looks amazing! Do you find that the FoamCoat makes it heavier than fiberglass would?

I really don't know, as I don't have any comparison. I have never fiberglassed something, nor held a similar sized piece to see. It is quite heavy though, but it was heavy-ish even before I started coating it.

 

[Cayce]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Very nice work. I have spent several hours on the jaw piece and have started the faceplate as well.
I have had such a hard time on those detail pieces with the valley folds that it is ready for the scrap heap.
I will finish it for the experience of building the helmet (thankfully it's not my first pep pieces) once so i understand how it works and can get a better feel for the sizing vs. the tester I did.

How did you manage to get the valley folds so clean and sharp? Mine seem to bunch up the paper, and by the time i have 'forced' it all together the shape is horrible and those detail lines are warped.

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Very nice work. I have spent several hours on the jaw piece and have started the faceplate as well.
I have had such a hard time on those detail pieces with the valley folds that it is ready for the scrap heap.
I will finish it for the experience of building the helmet (thankfully it's not my first pep pieces) once so i understand how it works and can get a better feel for the sizing vs. the tester I did.

How did you manage to get the valley folds so clean and sharp? Mine seem to bunch up the paper, and by the time i have 'forced' it all together the shape is horrible and those detail lines are warped.

I had quite a bit of problems on the back piece when I pepped. I spent about 10 hours on it, and it didnt work, which can be seen in my earlier posts.
What I did, and it isn't perfect by far, was i started on the bottom of the piece. The collar that goes behind your head, as it has that indented piece which helps hold the shape. I then, very painstakingly cut and scored and prefolded every piece. When I went to glue it on, I would glue on the first tab and let it dry completely, allowing me to pull and put tension in the piece, ensuring every number lined up. It was only towards the end, where the top piece is, and the main valley fold is, that i had issue. It took me nearly 2 hours to glue it on. It still wasn't 100% perfect, but its gone now, under all that foamcoat and glue.

 

[Infested]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Ill be watching this.

 

[P4r4dox86]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Unfortunately you can't change scales in Pepakura Viewer, you need the Pepakura Designer software which you can download as a trial for free.

In terms of scaling, you need to use the 2D menu > Edit > Measure Point to Point. You measure your body at a certain point, for example armpit to armpit in a straight line for the chest piece, then go into Measure Point to Point and measure the same point on the armour piece. If it's different you use the Scale option in the same 2D menu to change the scale factor to one that will give you a measurement that is the same, or at least close enough, to your own body measurement.

The main difference between the free trial and buying it is that you can't save your edited files until you purchase it. Just remember that the software doesn't take into account curves with it's measurements, so you need to measure yourself in a straight line and not using curves or it will be out of whack when you scale it.

Other than that, goodluck with your build mate, looks like you've got a good start and I'll be interested to see how the Foam Coat goes .

 

[NavyJester20]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Dude, your suit is totally awesome did you make your own template or are you using someone else's?

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Dude, your suit is totally awesome did you make your own template or are you using someone else's?

Well it is more of a helmet right now, might eventually become a suit. I used Shark's unfolded by dubeen. Don't quote me on the spelling. But it is a VI helm, and I will be modifying it in this stage to be a VII.

 

[Michael Wessels]

Re: The Perfectionists Ironman Mark VII - Large Update on Page 2 (Sept21)

Hey guys.

This last week I didn't work on the project at all. But haven't updated you guys in a while. Here is where I am at right now. I have probably put in about 75 hours now, not counting drying time and am really happy with it so far.

Let me know what you think! I attached the reference image that i have been using.
I think I am going to be cutting into three pieces soon so that I can work some areas better. I am excited for to see what it will look like! Any tips for what tool to use? I was thinking a small fine toothed handsaw and dremel with a cutting wheel.

 

[mmfox]

Your helmet in card stock had so great detail that it is a pity that you will need to do some re work to get there again. you already had it! :confused
Anyway, who can say anything about this, it looks really good dude.. keep it up.. I will follow your work!! opcorn

 

[tgk]

Michael, For cutting straight lines Lee Valley tools has some very thin bladed japanese saws but be warned they are expensive. Good luck your build looks great so far.