WIP: Foam Hulkbuster for my 7yr old - Lots of Con Pics!

Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

I can't wait to see the finished product. Very interesting build thred, thank you for sharing.

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Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

For real, this is super cool! And those arc reactors are really going to make it pop on Halloween night
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

Last night was pretty busy so I only got the two thrusters done on the back. I had to try a couple of different things get these built in 3mm foam, so they look little rougher than I'd like... but workable. I'll just fix them up in post. :)
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With everything else going on with this unit, I opted to just use bright white plastic and no lights for the inside of these thrusters. The blue tape is just to mask that white plastic when I'm painting it.

Here's a close up...
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This wraps up the back and moves my focus to the front of the chest/torso. More to come...
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

Plans & Musings...

As I've mentioned before, the Hulkbuster suit is NOT proportioned like a normal human. The top of the head is almost level with the top of the shoulders, the torso is truncated and the legs are elongated. 'Hiding' a small human in this suit is rather difficult. Most builders solve this by using stilts - this lengthens the legs and allows the human's torso to ride in the torso/chest of the suit. Tom (BumblebeeRecycd) of Extreme Costume's Hulkbuster build is a GREAT example of this - and well-worth checking out! :)

For my 7yr old, I don't want him up on stilts, so I'm going to have to really play around with the proportions to avoid making this look 'silly'. To start off with, I scaled the upper body of the suit larger than the lower half. This SHOULD provide me the ability to create the appearance of a more truncated torso. It also means I'll be having my kiddo looking out of the suit between the chest armor plates and the Hulkbuster head. The chest framework you've seen will house my son's head and shoulders - as well as provide the connection point for the massive arms. These will just hang loose, until he uses his black-clothed arms to animate them (via simple puppetry).

Here's a look at a really quick and terribly inaccurate drawing of these upper body plans (don't judge)...
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OK, here's my concern... With the weight of the chest framework, electronics, massive arms and foam constructed body panels - I want to make sure it doesn't pull him over! :facepalm

As this thing is sorta perched on the top of his shoulders, I'm looking for some way to better attach those shoulder pads to his chest. The last thing I want is him to fall over or for this section to just pull up and off him during Halloween.
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My initial thoughts were to create a sort of VEST (like a swim vest) with nylon belts that would somehow attach to those shoulder pads to his upper body. But attaching just foam to these metal bands won't work by itself - as the foam would just rip off the metal under stress. Maybe foam 'vest' and then glue/bolt some riveted nylon rigging OVER the top of these bands (so they are sandwiched between the foam 'vest' below them and the nylon straps on the top??

Thoughts? I'm I missing a very simple and straight-forward solution???

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Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

I think the vest is a good idea (or something like a climbing harness could work too). Can you bolt the strapping (using washers to distribute the stress so the bolts won't pull through the webbing/foam) directly to the shoulder pieces, and then add clips or buckles lower on his chest so he can remove it easier?
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

Danger was sitting at the table when I pulled up this page. As I predicted, he's losing his mind on the coolness of this! SO awesome! I can't wait until my two are a little older for stuff like this. It's just been within the last few months that Danger has gotten into superheroes.
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

My initial thoughts were to create a sort of VEST (like a swim vest) with nylon belts that would somehow attach to those shoulder pads to his upper body. But attaching just foam to these metal bands won't work by itself - as the foam would just rip off the metal under stress. Maybe foam 'vest' and then glue/bolt some riveted nylon rigging OVER the top of these bands (so they are sandwiched between the foam 'vest' below them and the nylon straps on the top??

Thoughts? I'm I missing a very simple and straight-forward solution???

You could attach four nylon straps (one at each end point of the shoulder pads) that end in a loop at his waist. The upper body could be held in place by a belt running though those straps, and through the belt loops on his pants. Should be secure, and any shifting of the upper body section should be tugging at his center of gravity rather than his extremities. Something like this:

sgsSR53.jpg
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

You could attach four nylon straps (one at each end point of the shoulder pads) that end in a loop at his waist. The upper body could be held in place by a belt running though those straps, and through the belt loops on his pants. Should be secure, and any shifting of the upper body section should be tugging at his center of gravity rather than his extremities.

That's a good idea... I just might have to sew belt loops on his pants - as the current plan is for him to wear black stretch pants/shirt under the costume.

Sorry I haven't updated this lately, family stuff has come up and I've had to take care of that before getting back to build. My plan is to marathon build this weekend (even though I'll have all four kids solo as my wife will be presenting at a convention this weekend). We'll see how it goes!

Until then, here's a pic of the leg pieces after their final clear coat was dry:
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SO, glad I'm making this out of foam... On the way to take this photo, I dropped the thigh piece right as I was closing my workshop door and it was CRUSHED in the door. It definitely created some hairline cracks in the clear coat, but otherwise it still looks great! I can't imagine how messed up it would have been if it would have been a hardened piece!
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

That's a good idea... I just might have to sew belt loops on his pants - as the current plan is for him to wear black stretch pants/shirt under the costume.

Sorry I haven't updated this lately, family stuff has come up and I've had to take care of that before getting back to build. My plan is to marathon build this weekend (even though I'll have all four kids solo as my wife will be presenting at a convention this weekend). We'll see how it goes!

Until then, here's a pic of the leg pieces after their final clear coat was dry:
https://c2.staticflickr.com/6/5820/21597356580_9f9ff45ffe_z.jpg

SO, glad I'm making this out of foam... On the way to take this photo, I dropped the thigh piece right as I was closing my workshop door and it was CRUSHED in the door. It definitely created some hairline cracks in the clear coat, but otherwise it still looks great! I can't imagine how messed up it would have been if it would have been a hardened piece!
Finish on that looks excellent

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Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

:popcorn :popcorn :popcorn

Just awesome as usual!

How hard would it be to convert these files for an adult...just curious..ASKING FOR FRIEND! :lol
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

:popcorn :popcorn :popcorn

Just awesome as usual!

How hard would it be to convert these files for an adult...just curious..ASKING FOR FRIEND! :lol

The files in the first post are pdf's and designed to create a paper 'action figure' about two feet tall. I've basically doubled them to make a roughly 4ft tall version. You'd have to scale this up x6 to get something in a 1:1 range (~12ft tall). That would take either a VERY large printer or cutting up the pieces manually into much smaller sections in photo editing software... which would NOT be fun. :unsure

I'd think using Shadeling's files might be a less painful way to go. :thumbsup
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

Putting you in for Parent of The Year. Nice work!
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

This is looking amazing! I can't wait to see more progress.



:popcorn :popcorn :popcorn

Just awesome as usual!

How hard would it be to convert these files for an adult...just curious..ASKING FOR FRIEND! :lol

TurboTrey, there are adult version of this build including files in different threads. I'm sure you can find what you are looking for :)
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

:popcorn :popcorn :popcorn

Just awesome as usual!

How hard would it be to convert these files for an adult...just curious..ASKING FOR FRIEND! :lol

I believe SmookCMb has released these files for adult size
 
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Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

PM sent,T.T. I hope it is what you are looking for.
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

PM sent,T.T. I hope it is what you are looking for.

Hey, George, feel free to post a link to that thread or the files here. I'm all about sharing as much useful stuff as possible (from my build or others). :)
 
Re: WIP: Foam Hulkbuster for my 7yr old - Chest/Back Progress

Amazing! Fantastic job so far! Better hurry before your son hits that growth spurt. :)
 
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