duomaxwell1017's attempt to make an Iron Man costume

I have a question, I've started pepping an Iron Man Mark VI Armor. I have a few pieces completed, but I am wondering if there is anything that I can put on the inside to stiffen or harden the card stock. At this time I am not planning on resining and fiberglassing. I just want to put something on the pepped out pieces do they don't lose their shape.

Any suggestions?
 
duomaxwell1017
Id suggest Paper Mache (Newspaper Strips covered in a paste - normally PVA Glue mixed with water)

--- It worked well enough for me last year, as i didnt have time to resin/FG anything - i only did 2 layers of Paper Mache and it become rigid and did not want to move at all
 
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So here is an update on the costume that Barrett Pote started working on. Barrett did the left thigh, and left shin. I did the rest. I still have a lot more work to do, but I will push on.
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This was the helmet that my cousin worked on before he passed away. I managed to get some work done on it today. At first I didn't think I could finish this helmet. There were cracks all over the place, and the face plate wouldn't fit. So after using some Bondo spot putty, and 220 grit sand paper, I got the face plate to sit a little more flush. Now I just need to put a couple layers of primer on. Then get some regular Bondo body filler to help close up some of the gaps near the face plate. Once the Bondo is dry, then I will sand it again, add another layer of primer. My goal is to complete this helmet (doing final color painting) and add a few layers of lacquer, to make it shiny and reflective.

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So here are some updated pictures of my cousin's helmet. Last night I did the bondo, and some sanding. Did some more sanding this morning. Now I need to add a layer of primer, I will probably need to add some spot putty to take care of the divots, and cracks.
 

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Did some more work on the helmet today. Added a layer of primer, did some spot putty, sanded down the spot putty, added another layer of primer. Almost getting there, just need to use the spot putty a couple more times,
 

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Did some more work on the helmet, did a little more bondo spot putting work. Sanded, put a couple layers of primer. I tried to put the final color for the face plate, but the spray can was spitting. And I ended up sanding off some of the final color but now I have to re sand, and re prime the face plate.
 

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More pictures of the primed helmet. Need to do a little more spot putty work to remove the remaining divots.
 

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So the Helmet that I was working on is complete, painted, eyes are lit, and I clear coated it.

I started working on the rest of the Mark VI, I have both arms completely pepped, I pepped out my own helmet. I am working on putting the right shin together. I have the pieces for the right thigh printed out, I just need to cut them out and glue them together. I still need to scale and redo the abs, scale and redo the shoulder bells.

So last night I started to fiberglass resin the outside of the pieces that are complete. It was really cold last night. Temp was in the 50's, and I never used fiberglass resin before, I mixed up my first batch, didn't use too much hardener, and I started coating the outside of the pieces. So I fiberglass resined the chest, helmet, face plate, left bicep, both forearms, both boots, both elbows, and half of the back. I was outside for a few hours, and the helmet never completely dried and hardened. So I put the pieces in boxes to dry, and put the boxes in my storage. When cleaning up, I started getting fiberglass resin all over my hands. I washed my hands like 4 times using different types of soap. Eventually I was able to get most of it off. (Note to self continue to wear rubber gloves when cleaning up.)
 
So I've restarted this project again. All of the pieces that I was working on were ruined. I tired to use fiberglass resin, with fiberglass cloth, but the weather was too cool, and the resin would never harden. So I had to toss everything. I redid the chest piece, and I was able to salvage the abs piece from my previous attempt. Luckily I didn't try to fiberglass resin it. and I have the chest piece and abs hot glued together. and I attached the chest with foam squares, and hot glue to the neck brace.
I was able to buy a license key for Pepakura, so now I can save my files. I also bought a small metal ruler that can't be bent to help to do the folds for the pieces. I had some pieces that were already scaled, printed, and cut out in bags. So I have both shin pieces completed. I have almost both forearms completed, need to finish gluing pieces together for the one forearm. I have one bicep done, and I have another already scaled and printed, but I noticed that one of the pieces got messed up. Flaps are overlapping each other. So I will probably have to rescale and reprint both bicep pieces. I have the palms, finger, both boots, hand guards, and helmet already scaled. I will just need to print, and cut those out. I have to scale the following pieces, back, thighs, cod, and back, and side parts of the abs. Long way to go! I will press on!
 
Welcome, I have an Mk-IV in progress thread is active.
I use foam from TNT cosplay, much better than the floor mats in cutting and assembly.
Reading and watching is the best resource, this is my first build and I'm pleased so far, you learn as you build.
I'd be glad to help and share techniques. I'll be adding 3D to my build after I complete this foam suit, I didn't want the distraction learning while I'm building...lol.
 
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