Raigals iron man mk 39 starboost/gemini, upperbody DONE

Raigal

Raigal

Active Member
Hi guys,

Been awhile since i posted something here (mainly because i was building and finished a Halo Reach Emile suit so yeah thats 405th stuff)
but started with a new project, and this time its the Iron man mk 39 starboost/gemini armor.

Plan on using high capacity flood LED lights and rig in a co2 system for a simulated jet pack system.
As for now here is some progress on the helmet and chest piece that i already got finished.

Helmet is gonna get a redo but 10% bigger and a nice coat of smooth on epsilon.

side shots:
12107822_1708972196005383_5699003990197896934_n.jpg 12105823_1708971986005404_6213433504734409567_n.jpg

hot glue lenses and the hexagon back piece:
12119184_1708972272672042_2298099040979488605_n.jpg 12118706_1708972236005379_9165131441562125475_n.jpg

gave it a quick seal and paint job:
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drawing and cutting in all the hexagon patterns,and then pop it with the heatgun:
IMAG1995.jpg IMAG1998.jpg

getting there :) :
IMAG1996.jpg IMAG1999.jpg

Everything seen here is ofcourse good ol' foam!
The back piece and thruster pack i will maybe do in high density foam as its need some support of the co2 jetpack system.

Will update asap :)
 
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Re: Iron man mk 39 starboost/gemini (pic heavy)

Really clean work with the hexagons, your template looks like it must have helped a lot. Must take a while cutting all those in.

Looking forward to seeing the jetpack idea.
 
Re: Iron man mk 39 starboost/gemini (pic heavy)

Ikras said:
Really clean work with the hexagons, your template looks like it must have helped a lot. Must take a while cutting all those in.

Looking forward to seeing the jetpack idea.
Click to expand...

thanks man, yeah i just took a hex pattern off of google, size it a bit to what i wanted, cut out 1 hex and start drawing away.

constantly moving and lining the hex further along. cut in each one and pop it with the heatgun, it took forever and my back was in real pain afterwards :p

i record all my workshop sessions on my gopro, once the whole suit is finished im gonna make a new (big) tutorial series from start to finish.
 
Re: Iron man mk 39 starboost/gemini (pic heavy)

Looks awesome! I just started a starboost/gemini build as well, the pep files are pretty complex to unfold. Looks good though!
 
Re: Iron man mk 39 starboost/gemini (pic heavy)

i should update this more often as im way further along now :p so here goes:

since my last post i continued the work and started on the back piece, this piece was the most difficult part so far:
12241618_1731957153706887_3332028088833697462_n.jpg 12274428_1731957140373555_7052357278619300677_n.jpg

i also made the helm 10 precent bigger as the previous one didnt fit my big ol head, after putting it all together it looked a lil something like this:

905747_1733718216864114_4929671070049218891_o.jpg 12244336_1733718513530751_9205810559765205276_o.jpg

still lookin a bit scrawny right? nothing a couple of shoulders wont fix :p
12249976_1735810569988212_7517504755759453726_n.jpg 12310621_1748003808768888_6528363120875765429_n.jpg

couldnt resist a test fit ofcourse, also proceeded on the arm, i found files lacking in this area so freehanding to the rescue for a bitter fit and look
12369020_1753174521585150_5606416705612597167_n.jpg 12341603_1753174544918481_7792514474969111191_n.jpg

also made a half mannequin on a stand so i could display it easier for now and work/draw on it if needed, finished the arms and filled in alot of gaps in the (under)armor
IMAG2211.jpg IMAG2210.jpg

as for the elbows, made some flexible joints inbetween the biceps and forearms, several rings that hold together through elastic straps and can move independantly

coated the helmet in Smooth-on Epsilon, so onwards with all the sanding! :p
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its getting smoother every day
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thats it for now people! around the holidays i didnt get much time to work on it but as all that crap is over now we can get back into the grind and get this suit really moving!
i will try to keep it more updated regularly instead of these enormous pic heavy posts all at once :p
 

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Last edited by a moderator:
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Very nicely done! I wish i was as fast with building my armor as you are! Everything looking very smooth! Are you using Pepcowboys files? Most of the parts look very familiar! :D Im really looking forward to see the thing finished! Also I am very interested to see, how you implement the co2 system, I wanna add that to mine too!
 
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Oh also another thing, can you make a detailed picture of how you attached the Shoulders to the Torso? Thank you in advance! :)
 
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Cri7e said:
Oh also another thing, can you make a detailed picture of how you attached the Shoulders to the Torso? Thank you in advance! :)
Click to expand...

so far its pepcowboys file indeed except for the biceps, those i freehanded (the files didnt look good in my opinion)
the forearms i adapted aswell to give them a slimmed down look.

co2 system is still gonna be challenge, still need to buy most of the stuff but should start on that in a few weeks
for now im sanding the helmet to make it worthy for molding and casting
12571357_10153595534194093_2067592111_n.jpg 12570963_10153595534429093_998055525_n.jpg


as for the attatchement pictures of the shoulders here you are :p

pic 1 is shoulder with 2x10mm foam pieces slammed together to function as a spacer
pic2 is the torso where you can see the other side of the buckle sticking out
12511863_10153595541559093_195037071_n.jpg12570905_10153595538224093_1367374877_n.jpg

pic 3 you can see that underneath it (torso) i slammed 2 of those 10mm foam cutouts aswell to make it allign so that it actually sticks out
and pic 4 well... clickity click em together and its done
12511989_10153595538269093_65045205_n.jpg 12540283_10153595538374093_1481187686_n.jpg

pic5: and you go on like that also for the rest, like the bicep to the shoulder :)
12583780_10153595538539093_389227573_n.jpg
 
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Raigal said:
so far its pepcowboys file indeed except for the biceps, those i freehanded (the files didnt look good in my opinion)
the forearms i adapted aswell to give them a slimmed down look.

co2 system is still gonna be challenge, still need to buy most of the stuff but should start on that in a few weeks
for now im sanding the helmet to make it worthy for molding and casting
View attachment 577529 View attachment 577530


as for the attatchement pictures of the shoulders here you are :p

pic 1 is shoulder with 2x10mm foam pieces slammed together to function as a spacer
pic2 is the torso where you can see the other side of the buckle sticking out
View attachment 577531View attachment 577532

pic 3 you can see that underneath it (torso) i slammed 2 of those 10mm foam cutouts aswell to make it allign so that it actually sticks out
and pic 4 well... clickity click em together and its done
View attachment 577534 View attachment 577535

pic5: and you go on like that also for the rest, like the bicep to the shoulder :)
View attachment 577536
Click to expand...

Thanks for the quick answer! Yeah Im gonna redo my shoulders too, eventually! Mine dondt really turn out the way I wanted them, yours look great!

I had to slim down the Biceps aswell, they were way too big in PepCowboys files, my arm could have fit in there 3 times ! :D

I have one question on the shoulder attachments, does the clip not rub on your shoulder when you wear the armor or do you have another foam layer underneath so that it is comfortable? Thanks for the detailed pictures! Most of the time I have an idea of how I want to connect something but no real plan!

And also I cannot wait for the CO2 system updates!
 
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Cri7e said:
I have one question on the shoulder attachments, does the clip not rub on your shoulder when you wear the armor or do you have another foam layer underneath so that it is comfortable?
Click to expand...

i wear stretch suits underneath the armor so no, the clips dont bother me at all, i always do it like this actually.
 
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Awesome work!!! I'm also working on pepcowboy's Mk 39 suit, but in paper/fiberglass... so I'm going the long, dusty way around the block. Something about foam just bugs me.... I think I just need to work it a bit.

For the hex pattern, I was planning on making a 50cm x 50cm sheet template of it via CNC, molding it up and casting it in silicon or rubber and cutting the parts I need and fitting them in place.

I was also thinking about having the hole face plate of the helmet made from a gold-tinted one-way acrylic mirror formed over a buck, but I'm not there yet and still trying to find out from various manufacturers if it's doable.

Keep up the great work.
 
Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

Teddz said:
Awesome work!!! I'm also working on pepcowboy's Mk 39 suit, but in paper/fiberglass... so I'm going the long, dusty way around the block. Something about foam just bugs me.... I think I just need to work it a bit.

For the hex pattern, I was planning on making a 50cm x 50cm sheet template of it via CNC, molding it up and casting it in silicon or rubber and cutting the parts I need and fitting them in place.

I was also thinking about having the hole face plate of the helmet made from a gold-tinted one-way acrylic mirror formed over a buck, but I'm not there yet and still trying to find out from various manufacturers if it's doable.

Keep up the great work.
Click to expand...

nice plans on the 1 way mirror, mine will just be casted in smoothcast 300 when im done with all the sanding and then ofcourse mold it :)
other than that been just busy with more sanding

traced out all the detail lines with a pencil and gonna carve in the details with needle files
when thats all done im gonna wet sand it all and its rebound 25 time :D

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Re: Iron man mk 39 starboost/gemini (BIG update and even more pic heavy)

and the helmet is done!
its gonna be molded tonight, jacket mold tomorrow and casted the day after that.

gonna make a project run soon on the forum (better get that premium status :D )

IMAG2440.jpg
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Re: Iron man mk 39 starboost/gemini (molding the helmet)

Molding and first cast is DONE! :D
we made a timelapse of the past 3 days and edited it into a 3 and a half minute video, enjoy ;)

 
Last edited by a moderator:
Re: Iron man mk 39 starboost/gemini (molding the helmet)

Cat is awesome on 0.00-0.12.
Oh, and nice helmets! yes, they nice to:cool
 
Re: Iron man mk 39 starboost/gemini (molding the helmet)

hehe glad to see someone noticed ;)
in the original non time lapsed footage she stood there for 5 and a half minutes :p
 
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