Tips from Newbie to Newbies (on foam build - for now)

Hey don't know if this is ok to ask but do you have the mark 8 pod that I can use to make my own parts or is that out of line ?


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The cod (hence the pod) for Mk8 is still on progress.
This is a tips thread, for sharing some useful tips.
You might wanna post on my Mk8 WIP or PM me.
 
I'm not sure who you're asking, but as for mine, I'd say around $400. But it was spread out over several months. So it wasn't that bad of a hit.
 
These are awesome tips! I think I'll do another thread on foam building tips with the type of foam I'm using. Everyone else is using thinner foam that I can't get ahold of here in Texas. Thanks for the inspirations here and I'll definately be following this for sure!
 
Amazingly helpful, I will be starting my build pretty soon here and I am new to the foam, pep, ect (armor building in general)

Excited!
 
I do have one. When hot-gluing my pieces together, a tiny bit escapes from the seam. Did this happen to you? And if so, how was the easiest way to get the excess off? Just pull it off? Melt it? Leave it?
 
Depending on how big the gap and how much is the excess.
I'll give you several options:

1. Pull it by hand or use cutter for cleaner result. Normally this is for tiny blots.

2. Use masking tape on the outer side before glue, put the glue from the inside. When the glue gets cooler, you can remove the tape. A bit of extra work, but it will make the cleanest seam.

3. Pull back the glue rod, and use the tip of the glue gun to smear the excess glue. I am using this technique right now.

4. Wipe the excess glue right away when it is still (a bit) hot with your thumb. You need to have a superhero thub to do it, or with practice, you can time yourself. I used excess foam :love to save my thumb.

Hope it helps.
 
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Depending on how much escapes and if it is still in kind of a blob, but hasn't been smeared on the edges, you can use sharp scissors to snip off the excess that is sticking up too.
 
Yeah; I'm using the glue gun-melt method right now. I never would have thought to place masking tape on it before gluing--genius!!!
 
2 other ones that popped in my head:

-And I'm working on the mark VI chest now; any specific tips?

-And do you think it is worth the money to invest in a heat gun? The ones I can find here are around $100--is it worth it? I'd use it to bend the foam on the helmet to get the right curve and to maybe heat-seal the entire suit. For my purposes, do you think my wife's hair dryer is sufficient?
 
masking tape is not my idea, it was familyman. He is genius!
See his website here
Seamless joins - Costumes are cool.....

On Mk VI chest, I'd recommend using 10mm or 8mm. 10mm is actually nice. I did it once and it didn't turn out good, but it was way before I got some tricks in my sleeves. I mod the template to fit my style with 10mm, but haven't got a chance to do it.
Please be specific on what you need.
I'd recommend to use JFcustom's template. He is another genius.

As for the heat gun, familyman got an alternative.
I use open flame from my range top (I can't afford to buy heat gun).
Depending on the wattage of the dryer, you can or can't use it.
Rule of thumb is to try.

For seal, I prefer to PVA or coat with roof sealant.
An iron also can be used.
 
Okay as someone who's a noob, this is amazingly helpful. THANK you so much, u've saved countless hours!

I have a quick question: is there a big difference between pepakura files for foam, paper, and cardboard?

I want to create a youtube video with the suit and make it feel as real as the movies in terms of what it can do (fly, repulsion blasts, chick magnet etc). I'm hoping to get this out around the same time as the Iron Man 3 release. So I'd need to get this costume done within 1 1/2 months (2 weeks for editing =). I literally can dedicate every single full day to working on this. Do you guys think this is possible?? lol... I may be over my head in this.

I'm a noob at building pepakura designs, but from what I gathered, foam would be the fastest. And also it seems the hardest part to make foam look good is not so much the construction, but the paint job. I've been reading this forum for the whole week lol.
 
Thank you.
Pepakura for foam build is a bit "simplified" version of paper build. Best way to illustrated: paper have almost no thickness , where foam can be vary from 2-10mm. So if you want to make a box (50x750x10mm) for example, in foam you can just cut 50x750mm rectangle from 10mm foam. Where in the paper build, you need to have 2 pieces of 50x750mm, 2 pieces of 50x10mm and 2 pieces of 750x10mm. Hope you understand the concept.

I covered plus and minus in foam and paper build in previous thread too.

As for cardboard, depending on what kind of cardboard. For corrugated cardboard, use foam template. For duplex (or some will refer it as cereal box), use paper template. I am thru with corrugated. I will be experimenting with duplex, and I will update info/tips regarding this when I finish playing with it.

My suit can't fly, nor it has repulsor blast, but it surely a chick magnet :love(see my link below). If you can make the suit fly, please post the WIP, because you will be refer as RPF's GOD.

JFcustom created a very "easy" foam template so it can cut down building hours a lot. The down side is that you'll loose the detail more.

If you haven't build foam customes, I'd suggest that you try a simple one first. Mk4/6 is a good way to start. MK5 and Mk8 is not for beginner (not trying to be snob, but it IS difficult to build). But nothing is impossible, all you need is to do, there is no trying, and practice makes it better.
 
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Thanks for the explanation IMIM2! (by the way I don't intend on making my suit fly for real lol... it's all going to be via visual effects... but not the crappy kind)

So I'm budgeting everything atm, and I was wondering what are all the tools/materials that I need for a foam build?

From what I gathered this is all I need, if I'm missing something please let me know:

Assembly tools & materials (from starkswarehouse.com & STEALTH's tutorials):
Card Stock paper 110 lb/175 GSM
Cutting mat
Steel Ruler
Masking Tape
Disposable Cutting Knife & X-Acto Foam Knive
Plastazote Foam or EVA foam 6mm-10mm depending on preference
Wax Crayons or markers - for tracing
Glue Gun
lots of Glue Sticks
Buckles & "backpack thread" for connecting parts
Velcro for sticking parts onto the suit

Paint tools and Materials (using XRobot's method):
PVA glue
Smooth Cast 65 D
Brushes
Acetone for cleaning brushes
Standard rattle can Spray Paint

I also heard some ppl using a dremel rotary tool... is this necessary?
Anyway, if I'm missing something on this list please let me know as I'm sure it will help other noobs searching through this thread!
 
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I use regular paperjet paper 80gsm instead of card stock.
The paper actually used paper (I print at the back).
Just personal preference ( I am cheap :lol).

If you use plaztode, you can use a pin, to pin down your tempalate to the foam, so you don't have to trace it (I forgot whose idea it was, sorry)
I tried on the EVA,it leaves a bit of punch mark, so I drop the idea (but actually it is a very good idea)

I use scissors instead of knife now, but again personal preference.
You probably do not need steel ruler
I have two glue gun, one for glue, and one for smear (no glue).

Might wanna look into rare earth magnets (and chick magnet too if it is available in your area)

PVA can be washed by regular water. Brushing resin probably can't be washed by acetone, it is asingle use brush.

Solder? what suit are you gonna build?

Dremel is used to clean the edges and fiberglass excess. If you do not want to go FB, or using Bondo/Rondo, you probably do not need dremel.

I am not sure what else I can think of.

I am more do it first type of guy. Some tools can be picked later on. Well, my dad got plenty of tools to borrow anyway.

Good luck
 
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