Bazza's Iron-Man suit build

[Barry]

Here's two pictures showing the hand plate in the open and closed positions. I still need to refine them, take the inside corner off and pad them underneath, but the hinge will have a switch under it that activates the hand repulsor illumination when it is pushed back by the back of the gauntlet.

There will be a return spring tacked on the inside as well to bring it back to the closed position snug against the back of my hands.

[Barry]

Today I had little time during lunch so I just added the toe recesses. I cut the rectangle out of the front of the toes, then made two small trays the same size as the hole about 5mm deep and tapped them in for a snug fit. I then set the MIG to low wire feed and enough juice to penetrate the .95 sheet and fuse them together.

A quick grind and you get the idea. More refined clean-up later.

[Barry]

Went to the powdercoaters today with the suit to come up with a plan. Basically because of the filler I need to use to smooth out imperfections and the temperatures required in the powder coating ovens, I can't powdercoat and must go to the auto-paint option.

Bummer. He was prepared to powdercoat for free as long as I paid for the powder.

[Airconvent]

Not too sure on the quality of finish but I guess any method will look good considering you put so much effort into it and your mates and the kids would love it too!

[Barry]

Not too sure on the quality of finish but I guess any method will look good considering you put so much effort into it and your mates and the kids would love it too!

I'll figure it out. Plenty of time before I'm ready for that stage anyway.

[Barry]

Canberra Times article. It will be in Sunday's paper. Hopefully with more pictures.

http://www.canberratimes.com.au/nationa ... 711-gi924p

[Airconvent]

You're a celebrity alright, mate!
But if you intend to make one for the little one, then I suggest you do it fast as they outgrow the suit very quickly.

[Barry]

You're a celebrity alright, mate!
But if you intend to make one for the little one, then I suggest you do it fast as they outgrow the suit very quickly.

That's what coloured foam and hot glue are for.

[Airconvent]

That's what coloured foam and hot glue are for.

[Barry]

Long time no see people! Three years later, I'm all but finished on the suit except for some tweaks and improvements.

I had my first public appearance in it a couple of months ago and it was a huge success, raising money for children's charities. Been all over TV, Radio and newspapers. I have another event in less than a month in Sydney then I should be getting into the children's hospitals.


Some shots from the day.























Get me outta this thing!



Ahh, pretend beer from a plastic Iron man mug...



Phew! Mission accomplished.