War Machine, my first Pepakura project...

Discussion in 'Marvel Costumes and Props' started by GordonTarpley, Oct 31, 2011.

Tags:
  1. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    [​IMG]


    I'm about 85% done with my first Pepakura project, the Iron Man 2 "War Machine". I got it up to a wearable level for Halloween but it still has quite a ways to go, loads of things I plan on fixing and missing parts to complete. I tried to take lots of photos of the process and I'll post them here with description as I have time. I'll try to be sure to give proper credit to the maker/s of the pep files as I post images of individual parts.

    The suit is a paper/fiberglass and foam hybrid suit and I'm actually planning on remaking a few of the fiberglass parts out of foam due to the comfort factor.

    This is about two months of work, after hours weekends, etc...
    With the amount of mistakes made I've learned a heap of "what NOT to do" and the next build (whatever that turns out to be) will go much more quickly and considerably smoother

    [​IMG]

    [​IMG]


    [​IMG]

    The eyes actually light up (the eyes are red now) but my setup is crap and too much light leaks inside the mask and makes it difficult to see out at night.
    It's almost fixed now and should be good to go by next time I have a chance to wear the costume.

    [​IMG]
     
    Last edited: Dec 14, 2011
  2. Hyperballistik

    Hyperballistik Member

    Trophy Points:
    192
    It looks really good, I can't really tell which parts you did with foam but i agree the pep stuff does get a little uncomfortable to wear, I did a complete pep suit that was based on Halo and it was heavy uncomfortable and hot, since I discovered how to build with foam its my prefered choice to build armor with, but awesome job on the War Machine
     
  3. SemperBourne

    SemperBourne Active Member

    Trophy Points:
    331
    Wow I love your war machine..looks awesome
     
  4. EyeofSauron

    EyeofSauron Master Member

    Trophy Points:
    2,671
    awesome :)
    you did this in two months?

    im on and of working on mine for 6 months now and its nowhere near as far as yours :D
     
  5. Pokeman

    Pokeman New Member

    Trophy Points:
    17
    Thats so true. I feel the exact same with my costume.

    That costume is sick!!! I'm kinda curious about that pepakura thingy, I've never tried it.
     
  6. EyeofSauron

    EyeofSauron Master Member

    Trophy Points:
    2,671
    its a hell of a lot work, but its pretty addictive :)
    i started with a helmet, and did the whole suit because i liked it so much

    but its not for everyone, you have to be very patient, and dont mind hot glue burns :)
     
  7. Graphic Jordan

    Graphic Jordan Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    1,456
    Great suit and I also see you live in Tampa Bay as these photos are in Ybor. I am in St. Petersburg, Glad to meet another local.
     
  8. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks for the kind words! :)

    I started out with and iron man mkVI helmet by cutting out lots and lots and lots of paper. I realized shortly that the paper I used was way too light weight and I just wasted loads of time. When I decided to start over War Machine seemed like it might be a little bit more fun. back to cutting paper and tiny little tabs...
    [​IMG]

    I pepped up the helmet, torso, shoulders and arms first.

    The first war machine paper helmet came out pretty decent. And yes, I did say "first". I began glassing the model and was making decent progress. I set it outside the to start the next round of resin coating and went inside to get some supplies. When I came back out, maybe 10 minutes later, a freak rain shower had happened and my helmet turned to deformed mush. So.... back to square one...
    [​IMG]


    [​IMG]

    Shortly after this I made the legs but didn't get any photos of them before glassing. :(


    Fiber glassing the parts came with a whole set of new challenges. I experimented with different methods on almost every part I built to see what would work best. On most of them, what seemed to work was a thing coat of resin on the outside of the piece first. On some of the parts I would do a second coat on the inside and let it cure before adding the fiber glass mat.

    One of the hardest parts to manage were large pieces with big, low detail areas. These were very prone to deform once the resin started to soak into the paper. I found that doing a few areas at a time worked better than trying to coat the whole thing. I would start in areas that needed lots of support and reinforce the seams, edges and corners with a light coat of resin and allow to cure before venturing out into the open areas. This helped the rigidity enough to keep the parts from collapsing under the full coat of resin.

    The shoulders were particularly tricky and wanted to curl in on themselves. I ended up using a box and building a support structure inside to help them hold their shape.

    [​IMG]

    The were both attached and needed to be cut apart.
    [​IMG]

    [​IMG]

    with a few distortions to fix and lots of filling and sanding to go, (plus a few other troubles I'll write about in a future post...) In the end, I was in too much of a time crunch to do all the extra work required on the shoulders so I moved over to a quick foam version which, I think, worked nicely (even better than expected) in such a pinch. and actually convinced me that more of the parts could have been made from foam.

    [​IMG]

    I will go back and finish the fiberglass versions in the future.

    Some more will be covered in the next post... got work to do. ;)
     
  9. EyeofSauron

    EyeofSauron Master Member

    Trophy Points:
    2,671
    as every WM project, im following this :)

    one tip: dont do arms and legs in Pep. you will thank me when you try to wear it (i did the whole suit in pep, arms and legs are painful to wear over time :)
     
  10. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    haha, you're SOOOO right. unfortunately I learned this the hard way!
    the arms and fiberglass shins are actually alright. I replaced a few parts of the shins with foam and they don't hurt to wear anymore. The thighs on the other hand.... OMFG. you should see the marks on my legs from halloween. terrible. I'm working on the full foam upgrade for those now. ;)
     
    Last edited: Nov 2, 2011
  11. SemperBourne

    SemperBourne Active Member

    Trophy Points:
    331
    x2 I have been mostly on wm threads because I am building one myself. I have noticed that there are way more iron man projects then wm.
     
  12. pRoJectEarth7

    pRoJectEarth7 Well-Known Member

    Trophy Points:
    866
    man... your war machine is pretty neat... awesome job:)(y)thumbsup!

    it reminded me of the first ever pep we did... unfortunately, we only managed to do the helm...Ironman/Warmachine Motorized faceplate pRoJectEarth7 - YouTube

    Our warmachine helm became a guinea pig for our first time molding process and was totally destroyed afterwards:cry

    Anyway, your build along with other WM thread here inspires me to rebuild our warmachine...

    thanks for the inspiration...

    cheers!
     
  13. Kormier

    Kormier Well-Known Member

    Trophy Points:
    556
    Working on wm pep myself. Thanks for the tips about using foam for some pieces, I will consider this.
    I have never seen anyone do the gattling gun on the shoulder... THAT would be neat! ( but probably heavy and bulky to wear). Great work. Inspiring.
     
  14. EyeofSauron

    EyeofSauron Master Member

    Trophy Points:
    2,671
    sure it has been done :)

    even working ones, with airsoft, or just with rotating barrels, or even only static :)

    look at masked riders build, his is probably the most accurate build :)
     
  15. Kormier

    Kormier Well-Known Member

    Trophy Points:
    556

    I just checked it out, that is awesome!!.... I had never seen one before.
     
  16. DarkKnightOfPA

    DarkKnightOfPA New Member

    Trophy Points:
    17
    Nice job. I've been looking at all the pep threads and it's making me really want to start a project like this. Just not sure I would have the patience.

    Oh, and I love the shot where it looks like War Machine is about to get attacked by a rabid Scooby Doo. :)
     
  17. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks! That helmet looked good! I want to motorize my faceplate too. got any tips before I start making lots of mistakes?!
     
  18. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    I'll be making the shoulder gun starting this week. (first version anyway, probably upgrade it later) I'll be sure to post some photos. Also getting ready to put up some pics of how i did my chest/back it's mostly fiberglass but has some foam parts that made a huge difference in wearability. check back later today or early tomorrow for a better description, maybe a quick video if i get some extra minutes...
     
    Last edited: Nov 3, 2011
  19. jayjayn

    jayjayn Well-Known Member

    Trophy Points:
    556
    great job, could u share the paint you used?
     
  20. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Sure! Nothing crazy was used, I got cheap stuff. For the metallic parts I used Krylon Matte Aluminum and the Grey parts are done with Rust-Oleum "Charcoal Grey" The foam pieces all had different treatments before painting, but used the same paints listed above as the final coat.

    i'm making some more parts this week and I'll do a comparison of the foam sealing methods and show my results.

    Both of the paints I used are slightly too reflective but after weathering the reflections were deadened some and I think it looked better.

    The weathering is a bet excessive and was done extremely quickly (literally 35 minutes or something before I went out for Halloween) I'd like that to look better so I'll be redoing the whole thing soon. paint, weathering, the whole nine yards.
     
  21. jayjayn

    jayjayn Well-Known Member

    Trophy Points:
    556
    great thx.. love the build.. im gonna start on wm build soon =D
     
  22. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    I'm starting the foam thighs tonight so I headed up to Wal Mart to get some xacto blades. While i was wandering around the newly rearranged store I found the floor mats, almost identical to what I've been buying from Home Depot BUT at WalMart you get 6 sheets of foam for $1.50 more than 4 sheets at Home Depot. Much better deal.

    The mats at Wal Mart are found in the isle with the exercise equipment.

    Looks like this...
    [​IMG]
    [​IMG]

    I think they still may be cheaper at Harbor Freight but that place isn't open in the middle of the night. ;)
     
  23. ewhite00

    ewhite00 New Member

    Trophy Points:
    2
    Wow, looks great! Good job, look forward to seeing the updates.

    Sent from my SAMSUNG-SGH-I997 using Tapatalk
     
  24. AndreaG

    AndreaG New Member

    Trophy Points:
    2
    Hi Gordon,
    You rule!
    I'm following your way, I've the same exercise mats ready to be cut! I just miss the x-acto blade (the one tht cuts 45 degree angles) as I cannot find it here.

    Please keep this post updated, I cannot wait to see your progress!
     
  25. Kal

    Kal Well-Known Member

    Trophy Points:
    566
    How thick are those mats?? I got the ones from Harbor F. But they are .5 every ones says they use 6mm. 6mm would be .25 so, did I buy the wrong stuff or is it the right stuff and every one else is just daying the wrong size?
     
  26. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thank you!

    Ready for an update? here we go..

    This is some of the process of the chest and back.

    When the chest was pepped it was done as one piece instead of a font and back. I think this actually made considerably more stable when I got around to the fiber glassing part but led to some strange areas that needed addressing....


    First, there was no hole for my neck...
    [​IMG]

    I cut this out with a Dremel using a cutting bit, then sanded down the excess
    [​IMG]



    [​IMG]

    After trying the parts out I ended up cutting back quite a bit more (see later photos...)


    Next step was separating the front from the back. I had some trouble deciding where to make the cuts until I figured out a plan for how they would be re-connectable. Obviously, the first think I did once they were cut is run inside and put them on in front of the mirror to determine the fit. I noticed right away that the parts along the sides that connect the front and back would be very uncomfortable. They were stiff, stuck out sort of funny and had a really ugly connecting point.

    [​IMG]

    Foam seemed like a good option to fix this so I started doing some modifications...
    [​IMG]



    [​IMG]


    I removed the pointy "flap"? section from the back with the dremel and using some paper and masking tape extended the flat area a few inches and added 2 layers of fiberglass mat
    I also cut down the front part of the connection considerably so there will be an overlap between the foam and the fiberglass parts. I'll get a photo of that in the next post....

    [​IMG]



    [​IMG]

    After the glass cured the area was trimmed down and cleaned up.




    Going through some of the Halloween weekend photos I've found that it becomes really easy to see the weak and strong points on the costume.
    BUT, from more than a few feet away, the difference in foam and fiberglass from the chest to the back is pretty seamless. (the midsection... that needs some serious tweaks but i'll get to that soon. ;)


    [​IMG]

    I'll be doing a "part 2" to this post after I take some more photos of the inside of the chest showing the connections.
     
  27. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks! I've been using a box cutter to do the main cutting then using an exacto (the smaller size "A" seems to work fine) for cutting the details and curves in the foam. I dont' have a 45 degree cutter but haven't had much problem doing it by hand. I was actually really nervous about it when I started but it's much easier than expected.


    The mats I've been using are .5 inch. (same size as harbor freight) they work fine. I've only needed anything thinner on two spots so far and for those spots, I just cut the foam in half. fillet it like a fish. I think the thinner stuff seems almost too thin for some of the larger areas but would probably work great for some things, like the neck and hands.
     
    Last edited: Nov 4, 2011
  28. SemperBourne

    SemperBourne Active Member

    Trophy Points:
    331
    Your chest piece looks awesome so far..great job dude
     
  29. Kal

    Kal Well-Known Member

    Trophy Points:
    566
    how did you hook the bicep to the gauntlet? I did not see a elbow file in the Foam WM temps. Also, what did you do for the FN2000 on the side of the gaunts?

    thanks
     
  30. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks!

    No connection at the moment. Right now the elbows are made from fiberglass. The forearms fit pretty snug on my arms and don't seem like they'll slide off but I did put a little loop in the inside of the hand guards to keep them from rotating around. No guns on the forearms yet but I'm going to try to get at least a temporary version done this week. I pepped some out of paper but I'm an idiot and ruined them. I'll post photos of that in a future post....
     
  31. Muscleflex

    Muscleflex New Member

    Trophy Points:
    16
    which pep file did you use? can you link pls?
     
  32. moe

    moe New Member

    Trophy Points:
    2
    Wow this looks amazing!
     
  33. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks!


    Yeah, I'll find them here soon. Check out Stealth's foam Iron Man page for a few. I used the foam Iron man template for the feet and neck. I also used the HD pepakura versions for most of the other parts. I'll try to link to the thread here if I can find it. I just finished converting the HD thigh file to work with foam.

    I had a chance to wear the suit at the Tampa Bay Comic Con this weekend (Tied for first place in the costume contest with another war machine!) .


    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    I've been trying to upgrade a few things since Halloween.
    They eyes have been redone and are much more compact now BUT the red diffuser, when moved closer to the LEDs, no longer makes the eyes glow red. SO, I'll be buying actual red LEDs sometime in the next few weeks and swap them.


    Still some finishing work to go on them but the new foam thighs were a lifesaver. SO much easier to walk around in, up and down stairs, no pinching.
    [​IMG]


    Also built a really quick version of the forearm guns. All made from foam scraps and old computer parts along with some random things i found around the house. Biggest problem with these is that the extra weight pulled the forearms lower on my arms than the previous times I wore the suit. I'll have to attach them to the bicep now or add some extra padding inside to prevent this for next time.
    [​IMG]
    These will eventually be replaced but I think they'll do for now.

    Almost finished the shoulder canon but couldn't quite pull the mounting system together in time for the con..
    [​IMG]


    I'll get an update with some new photos soon and better details/links to the pep files I used.

    Also, I'm planning on doing a video tour of the suit in the next few weeks. If anyone has requests on what you would like to see, weather it be on the suit, or more detail on how something was built, let me know and I'll try to incorporate it.
     
  34. royaltykustomz

    royaltykustomz Active Member

    Trophy Points:
    211
    this is wicked cool, good job.
     
  35. zeafour

    zeafour New Member

    Trophy Points:
    17
    Very VERY awsome.. the forearm guns are pretty serious looking too.... You scratch built those??
     
  36. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks!
    Yeah, I made them mostly from foam scraps. The greebly parts are mostly from an old computer. Anything that I found find doubles of. There is an old alarm clock there that i cut in half and use the speaker grills on both sides.
    [​IMG]

    I sanded the edges a bit since this photo which helped to even out the foam blocks before painting.

    The barrels are PVC tips, about 30 cents each. Also a few pieces of the ribbed mat I used for my C3PO belly.

    I'll clean them up some more as time permits and hopefully steer toward something more accurate.
     
  37. Blackdynamo2

    Blackdynamo2 Well-Known Member

    Trophy Points:
    567
    Nice Suit! You Got a Great Start. Stay On It, It Only Gets Better! - Keep Building!.......
     
  38. topshape

    topshape Member

    Trophy Points:
    191
    You make me sick! :lol I spent days trying to figure out how to make mine. Your guns do look slick though!
    Is the gatling made out of foam too? Could you post some pics of how you mount it to your suit? When I first made mine, I used PVC and it weighed a ton! It kept pulling my chest to one side. I remade it in foam, but it still pulls slightly.
    A bit of critque if I may. I notice your first ab plate, the one under the chest is connected to the rest of your abs. I think you would benefit by connecting it to the chest.
    Also, what colors did you use?
    I see you're slowly making the transition to foam. It's only a matter of time...

    Great work!
     
  39. GordonTarpley

    GordonTarpley Member

    Trophy Points:
    191
    Thanks!
    Yeah, you're right about the top ab. It keeps popping out when I move around BUT I have a fix for it that will work great as soon as I can set it up.
    I would (actually almost did) attach it to the chest but the way the chest/back fasten together it prevents the ab part from being mounted properly. Hard to explain but when I Take some video I'll be sure to show that so you can see what I mean.

    Right now the shoulder gun is partially foam, resin coated cardboard tube, and pvc. it's a little heavy but not horrible yet. I'll have it mounted to the suit soon but got a ton of work the last two weeks and it's putting a crimp on my personal time. ;)
    I made some PDF templates for it. I'll add them here when I clean the file up. not screen accurate but will worked with the supplies I had on hand. (PVC tubing, and Cardboard Tubes)
     
  40. STEALTH

    STEALTH Sr Member RPF PREMIUM MEMBER

    Trophy Points:
    2,080
    You tied...boo. You clearly won...cause he used the kid's helmet :p
     

Share This Page