Iron Man Suit

My second costume build attempt using foam flooring from home depot.

I began by downloading files from the web, using pepakura software as my designer/viewer program. From here, its print, cut, trace, repeat.

I decided to build this costume out of Foam. It was easier to work with, and took less time than a previous fiberglass build. I used hot glue to adhere the parts together, which was also nice and easy.

Next, I used a two part cast called "smooth on 65D" , and painted it on the outside of the helmet to give it a smooth, hardened look. It also gave it more strength. The downside was that painting it on left a lot of work for sanding, and then I had to apply 8-10 coats per part, just to get it to a nice thickness that i wanted. Needless to say, it was very time consuming, but worth it in the end.

Once all the pieces are measured and cut, the body parts get assembled one, by one. For the chest and back parts, I reinforced the structure using thick wire that was easy to bend and form into the inside of the foam, and still keep its shape, and gave it more structure.

Here I chose just flat black, very basic color scheme. I used some scrap wire for detail effects.

The arc reactor was a previous build that I did a while back... here is a link for that.

https://www.instructables.com/id/Arc-Reactor-3/

The chest parts were attached using velcro and straps. All leds, and electronic servos were powered by a few 9v batteries.

These were the most difficult to build, design, and make functional.

I did install servo's in the helmet, for the gun turret, and the jet pack. All are activated by a push button i modified on the chest piece for now.