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  1. sandbagger's Avatar
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    May 26, 2013, 10:11 AM - Sandbagger's Iron-Man builds - Now in STEEL #1

    *******Updated EDIT: I've now finished my THIRD Iron Man suit in FULL STEEL.

    Suit one - fibreglass bondo




    Suit two - cardboard



    Suit three - STEEL







    Last edited by sandbagger; May 10, 2017 at 8:22 AM. Reason: Project focus clarification.
  2. The Mandarin's Avatar
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    May 2013
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    Belgium
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    May 26, 2013, 10:19 AM - Re: Bazza's Iron-Man suit build #2

    looks really good!
    subscribed
  3. sandbagger's Avatar
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    May 27, 2013, 9:15 AM - Re: Bazza's Iron-Man suit build #3

    The Mandarin said: View Post
    looks really good!
    subscribed
    Thanks mate.

    Baz.
  4. sandbagger's Avatar
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    Jun 6, 2013, 9:53 AM - Re: Bazza's Iron-Man suit build #4

    Got busy building the cod-piece.

    Front


    Back
  5. Member Since
    May 2013
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    138
    Jun 6, 2013, 12:42 PM - Re: Bazza's Iron-Man suit build #5

    Looks great! What files are you using and have you tried on the cod? I'm doing my first build and need to see how it should fit with nothing else on.
  6. Member Since
    Apr 2013
    From
    houston,tx
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    Jun 6, 2013, 4:58 PM - Re: Bazza's Iron-Man suit build #6

    wow looking really good
  7. sandbagger's Avatar
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    Jun 12, 2013, 9:29 AM - Re: Bazza's Iron-Man suit build #7

    Djstorm100 said: View Post
    Looks great! What files are you using and have you tried on the cod? I'm doing my first build and need to see how it should fit with nothing else on.
    I'm using Robo's MK IV pep and yes, I've tried it on, but have to cut one side to get it past my hip.

    - - - Updated - - -

    Something I should have done in the very beginning -

    MAKE A TAPE DUMMY!

    Fitting, modifying and adjusting the suit needs to be done accurately and doing it on my own body is darned near impossible.

    With a tape dummy to my exact proportions, I can build and modify the whole suit on it and have it all fit together exactly, being sure that it will fit me when done.

    I watched some U-tube tutorials by STEALTH on how to make this.

    First a supporting frame has to be made out of PVC pipe. Then it's just a matter of putting on some thin clothes that you don't mind cutting up, tape up the sleeves, ankles and waist then get an assistant to wrap you up like a mummy in PVC Duct tape.

    I couldn't believe how good it made my back feel... I might have to tape up my back every day before a start swinging the chainsaw at work!

    Once covered from ankle to neck, then it's a matter of the assistant cutting the silver suit off - just enough to wriggle out of it, which can be slow and tedious, but taking your time is key.

    Next insert the skeleton support and start to tape up the cuts, leaving the torso open until last. Stuff the whole suit with newspaper, rags, sheets, foam or whatever you have and pack it right out. The tape won't stretch beyond how it was while you were wearing it, so your form is retained.

    I've run out of tape (used three rolls of 30 metres) so I'll have to pick up another roll tomorrow and stuff the suit as soon as possible.

    This is going down as one of the top few weirdest things I've done.....





  8. sandbagger's Avatar
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    Jun 12, 2013, 10:19 PM - Re: Bazza's Iron-Man suit build #8

    Tape dummy complete with some of the armour mounted on it.

  9. sandbagger's Avatar
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    Jun 16, 2013, 10:31 AM - Re: Bazza's Iron-Man suit build #9

    Here's one hip-pod I finished pepping tonight.

  10. sandbagger's Avatar
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    Jun 21, 2013, 11:27 AM - Re: Bazza's Iron-Man suit build #10

    Left thigh work in progress.

  11. sandbagger's Avatar
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    Jun 25, 2013, 10:26 AM - Re: Bazza's Iron-Man suit build #11

    Left thigh assembled. This one was a little more difficult than I expected. For such a large piece it is made of an incredible amount of small parts. Very fiddly cutting and folding on this one.

    This is the first part I've made that came with braces to go inside it for shaping. This way I can harden it then cut the braces out and it will retain the correct shape.

    I tried it on my leg and it fits perfectly, even allowing for thick and loose tracksuit pants, later to be replaced by bicycle long-johns and the padding inside the armour.






    I just laid the cod on the floor with the thigh under it and hip-pod attached to check for scale. Looks ok so far.



  12. Member Since
    Apr 2013
    From
    Derbyshire u.k.
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    110
    Jun 25, 2013, 11:52 AM - Re: Bazza's Iron-Man suit build #12

    That looks amazing
  13. Member Since
    Apr 2013
    From
    Fairfax, VA
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    17
    Jun 25, 2013, 1:43 PM - Re: Bazza's Iron-Man suit build #13

    sandbagger said: View Post
    Here's one hip-pod I finished pepping tonight.

    http://i.imgur.com/BmHOgOY.jpg
    Dang, that is a super clean pep. I always seem to have trouble pepping the circular pieces like the hip pods and ears. Any tips for getting it that clean?
  14. sandbagger's Avatar
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    Jun 25, 2013, 5:12 PM - Re: Bazza's Iron-Man suit build #14

    POEPOE93 said: View Post
    Dang, that is a super clean pep. I always seem to have trouble pepping the circular pieces like the hip pods and ears. Any tips for getting it that clean?
    I use an engineers ruler to make my folds by lining the fold up with the edge then pressing along the fold with my thumb. I'm using PVA wood glue which goes tacky pretty quickly, allows for a little bit of precise re-positioning then dries fast!
  15. Member Since
    May 2013
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    138
    Jun 25, 2013, 9:00 PM - Re: Bazza's Iron-Man suit build #15

    Hey mate, you can also score the fold line as well to make the fold cleaner and a little quicker.
  16. taijutens's Avatar
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    Sep 2012
    From
    Thailand
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    Jun 25, 2013, 9:22 PM - Re: Bazza's Iron-Man suit build #16

    Awesome ^ ^
  17. sandbagger's Avatar
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    Jul 6, 2013, 1:10 PM - Re: Bazza's Iron-Man suit build #17

    Shin assembled.





  18. Kryro's Avatar
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    May 2013
    From
    Essex, UK
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    Jul 6, 2013, 2:06 PM - Re: Bazza's Iron-Man suit build #18

    Oh my days - that hip pod - Brilliant pep skills there, so small but so hard to pep
  19. sandbagger's Avatar
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    Jul 7, 2013, 9:23 AM - Re: Bazza's Iron-Man suit build #19

    Kryro said: View Post
    Oh my days - that hip pod - Brilliant pep skills there, so small but so hard to pep
    Thanks champ.


    Checking for fit. By the time I get the inside fibreglassed and padded, then the undersuit - there won't be much room left in there. Should be a snug fit.



  20. sandbagger's Avatar
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    Jul 21, 2013, 5:58 AM - Re: Bazza's Iron-Man suit build #20

    I spent a few hours immersed in toxic organic fumes today in the shed, while sleet and snow outside kept the resin temperatures low.

    I painted the inside and outside of thigh and shin with resin, then bit at a time - poured in the slush-cast.

    One thing I would do in future, is tape the knee joint together before doing anything. I was lucky that the slush-cast was still a bit pliable so I could bend and squeeze the knee together then tape them in place while it sets properly. Before I line the inside with fibreglass matt, I will do the same again.
  21. LuciousFox's Avatar
    Member Since
    Jan 2013
    From
    England
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    Jul 21, 2013, 6:25 AM - Re: Bazza's Iron-Man suit build #21

    sleet and snow ? are you in the uk ?
  22. ModJob's Avatar
    Member Since
    Jun 2013
    From
    Manchester, UK
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    27
    Jul 21, 2013, 6:58 AM - Re: Bazza's Iron-Man suit build #22

    Cant be, Not with the awesome weather we're having right now luscious

    This is looking great dude, as its been said very nice pep work.

    I must must remember to make a tape dummy!!
  23. LuciousFox's Avatar
    Member Since
    Jan 2013
    From
    England
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    218
    Jul 21, 2013, 7:19 AM - Re: Bazza's Iron-Man suit build #23

    ModJob said: View Post
    Cant be, Not with the awesome weather we're having right now luscious

    This is looking great dude, as its been said very nice pep work.

    I must must remember to make a tape dummy!!
    That was what i was thinking ModJob

    Im loving seeing thease builds since at the moment im building a mk42 to promote the iron man 3 DVD release on 10 of September
  24. sandbagger's Avatar
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    Nov 2012
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    Jul 22, 2013, 6:51 AM - Re: Bazza's Iron-Man suit build #24

    LuciousFox said: View Post
    sleet and snow ? are you in the uk ?
    ModJob said: View Post
    Cant be, Not with the awesome weather we're having right now luscious

    This is looking great dude, as its been said very nice pep work.

    I must must remember to make a tape dummy!!
    Cheers guys. No, I'm in Canberra, Australia.

    - - - Updated - - -

    Ran into some problems with the knee joint aligning due to warping while resining. Here's a video to have a look why and a possible fix. Spread the word!

    Sandbagger.

  25. LuciousFox's Avatar
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    Jan 2013
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    England
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    218
    Jul 22, 2013, 6:58 AM - Re: Bazza's Iron-Man suit build #25

    could you do some cutting and re align the knee ?

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