I have started building an Iron Man costume, based off of the Mk. 6, from the movie Avengers. This post is covering the suit itself, and I will have a 2 follow up posts with a post explaining the electronics, and another to show the concluded project. This post will detail foam fabrication, which is how I am going to build my suit. This type of costume making is very popular for quite a few reasons. It is fairly cheap and easy.
Above is a reference picture of the iron man suit itself. This is what it should look like after painting. Below is a picture of my personal suit, which is blue, because my foam is blue. I will fix that after painting. The way I constructed this suit is very similar to my hulkbuster pepakura. I am using the Pepakura software again, but I have now purchased the premium edition, so I can change the scale of the model to fit me. For foam costume making, find the costume model you want, and print out the template sheets. Once you have you temples, cut the foam pieces out as you go, otherwise you end up with a mess. Cut out your piece of paper, and trace it onto some foam with a sharpie marker
. Any type of shop floor mat will work for this. Cut out the piece from your foam, and hot glue the pieces together as the computer software tells you to!
That is almost the entire fabrication process. Next, is painting. Since we are using foam, we cant use paint immediately, since the foam would absorb the paint. You need to coat the foam in a thick substance first, I use Plasti-dip, a rubber based spray. 2-3 coats of plasti-dip is recommended, but you can just keep painting until you no longer see the base color of your foam. After the plasti-dip is dried, you can paint the foam just like any other material. That is all there is to it! Stay tuned for future updates, and thanks for reading.