Bazza's Iron-Man suit build

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Barry
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Bazza's Iron-Man suit build

Post by Barry » Sun Feb 17, 2013 10:33 pm

Hey guys and girls, I thought a few of you might appreciate this for fun.

I've been building an Iron-Man suit to fit me, using a technique called Pepakura. It starts off with a paper chassis, scaled to fit and printed off on A4 card stock. It is then cut out in all it's pieces, folded, glued together then painted inside and out with fibreglass resin. Then you mix resin with car-body filler to make a slush-cast, pour it on the inside and slush it all around. Then you coat the inside with fibreglass mat for strength. Then you paste car-body filler on the outside and start sanding, shaping and detailing. Finally, undercoats, painting and kit the inside out with padding, lights, and in my case, some animatronics to make parts move.

This is where I'm at so far, as of mid-Feb 2013.....

The helmet

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And a short video of the faceplate moving:

http://www.youtube.com/watch?v=Wb9q0Rv7_OM=youtu.be

The arc reactor

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The suit

The suit is now ready for the bench. Now that the waist is hardened, it's time to fit it inside the torso to begin hardening the torso in shape. While the fibreglass inside was curing, I modified the arc-reactor and fit it inside it's housing in the torso. I found a beautiful big glass lens out of an old overhead projector and it fits EXACTLY over the top of the arc-reactor, sealing it into the suit.

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The entire build is on my ASIGN website, as a rainy day project. >>> http://www.asignobservatoryii.com/apps/ ... d=13968067

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Gary
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Re: Bazza's Iron-Man suit build

Post by Gary » Sun Feb 17, 2013 11:22 pm

WOW! Awesome! How's the rocket boosters coming along? :)
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Barry
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Re: Bazza's Iron-Man suit build

Post by Barry » Mon Feb 18, 2013 4:10 am

Gary wrote:WOW! Awesome! How's the rocket boosters coming along? :)
It's strange how I get that question a lot.... [smilie=ahaaah.gif]

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Airconvent
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Re: Bazza's Iron-Man suit build

Post by Airconvent » Mon Feb 18, 2013 9:00 pm

Awesome Barry but how do you see from inside? HUD like Stark's suit? :)
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Barry
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Re: Bazza's Iron-Man suit build

Post by Barry » Mon Feb 18, 2013 11:13 pm

Airconvent wrote:Awesome Barry but how do you see from inside? HUD like Stark's suit? :)
I can see through the lenses.

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cataclysm
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Re: Bazza's Iron-Man suit build

Post by cataclysm » Tue Feb 19, 2013 10:42 pm

COOL!

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Barry
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Re: Bazza's Iron-Man suit build

Post by Barry » Sat Feb 23, 2013 4:57 pm

Coming together...

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VinSnr
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Re: Bazza's Iron-Man suit build

Post by VinSnr » Sat Feb 23, 2013 5:27 pm

Barry wrote:Coming together...

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You are the man.....

Maybe Hollywood will be calling you soon . Robert Downey Jr is getting too expensive..hahaha

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Barry
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Re: Bazza's Iron-Man suit build

Post by Barry » Wed Feb 27, 2013 6:32 pm

1. I've found that a very light spray of colour (and I mean light), can help in the sanding process to clearly identify low-spots. The downside is that if you spray too heavy, the paint can very quickly clog your sandpaper.
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2. Rough filler application continues around the left side.
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3. Now getting a bit of an idea of symmetry for adjustment.
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Barry
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Re: Bazza's Iron-Man suit build

Post by Barry » Sat Mar 02, 2013 3:53 pm

I've been trying several iterations of arc reactor because the first one is not bright enough. I think I'm happy with this third attempt.

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The sanding continues.

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