War Machine MK1 Pepakura Foam HD Build - Iron Man 2

Thanks Radigast. I can't wait to see it done too ...so long in work.

I've seen people do that with heat guns, even hair dryers, although I don't feel it's necessary to do that to a whole suit as a pre-painting step. I only tend to use a heat gun to help shape the foam for complex curves. The PVA glue coating (I do about 50/50 Modge Podge and water) does the trick just fine with a few coats. Others add additional steps and/or Plati-dip and adhesive promoters before painting - I haven't done that.
 
Started glueing abs and cod together. Here's another example of getting some details with foam by undercutting and layering pieces (compare to the 3D pep model).
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For getting even spacing for indents, like the slots on the abs, I used a 2mm piece of scrap foam as a spacer, then glued from behind. Doing this gets you a nice, straight inset.

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Abs done. These are three separate sections that I'll link together inside the costume with elastic straps.
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On to the cod, starting with the back, "tailbone" piece... which was difficult, and that's an understatement. Whoever designed this was simply evil ;)

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Feel like I have a steady build pace going again! Only have a few more pieces to glue to complete the cod. I'm still not decided on where to have the opening seam (Velcro backed) so I can put it on more easily; thinking ahead to assembling parts and in what order I'll be putting on sections. I'm thinking I'll do that on the right hip rather than the front or back. I don't like having obvious seams. Any other ideas are welcome.
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If you have parts you think might be tough to completely cover with paint later, either because of size, shape, or location here's a good trick. Use a Sharpie that's close to the color of the paint you'll be using, and pre-color the parts. The tailbone piece on the War Machine armor is a good example.

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Trying to smooth out some of the angles in the thigh templates, but it's a little tricky in spots. It's handy to have variable circle templates on hand if you want to do this.
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Started cutting out upper leg parts and plan to start glueing this weekend. My circle cutter proved useful again for adding details on the side-thigh part!
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I'm using a heat gun to shape and seal the foam, for example on the front of the thighs. The heat gun also expands shallow cuts I made for detail lines that I added (based on reference images of the MK 1 War Machine). Picked up this technique from Stealth @ "Heroes Workshop" - check it out!

In the picture you can see the difference pre- and post heat gun on left/right thigh parts.
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This is excellent Sir. Do you have any for Iron Man? I am just beginning to make this stuff, currently working on my Mandalorian. Friend of mine wants Iron Man Armor is Tony Stark incarnate. :)
 
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