Build Your Own Ironman Suit 2008

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Introduction: Build Your Own Ironman Suit 2008

Please read little squares for more info.
I will have this project completed by October 26 2008.

I am going to assume that if you are considering this project that you have consulted the following book:

The Prop Builder's Molding & Casting Handbook
by Thurston James.

If you haven't at least looked @ this book -
DO NOT ATTMPT THIS PROJECT
You will make expensive mistakes & frustrate yourself.

If you have questions regarding the steps or ideas used to produce this project :
Feel free to ask - I only ask that you post them as comments because i may not reply to e-mails & I will most certainly post answers.

Step 1: Initial Cast From Mold...

This is the original casting that was removed from my alginate mold.
I am assuming that you have an item or have created an item to copy.

As you can see - the detail is present but there will be alot of aesthetic work to be done.
Bondo is a touchy material & there will always be some cover up to do.
I use bondo because it sets up fast & is easy to work with - sands easy & accepts paint well.
It is also relatively lightweight

BONDO IS EXTREMELY MESSY & THE DUST CAN KILL - WORK WITH SMARTS & PROTECT YOURSELF.

Step 2: Initial Trimming & Such

This is the point in which lots of dust is produced.
I use a drill press armed with a grinding stone to remove all unnecessary material.
This is the first sanding step & believe me - you will get really sick of sanding with this project.

I will need to use a dremmel tool to finish the eye work & dental picks to clean out the grooves of any goofs.

I did these first 3 steps in about 4 hours.

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58 Comments

Hi this is edwin and i have made an flight stablisher at home not that it took me 1000 of feet but yes i have made one and tested it. It took me 5 feets but then the consquences were bad. It stop working and i land on the ground very hard. We first though that there must be something wrong but then we figure it out. There was lekage in the boots. Also it caught a little fire. I use an plasma actaute in it. Maybe if you have any idea please give.

I completed with the help of my parents, relatives, and my cousins

I am 12 and i builded my My Iron Man Armor It is Mark VI it was completed two Years back

Kool i was thinking that someone will eventually make one, I've made designs for a suit of my own I'm focusing more on what its made out of eg metal and what is part of it like coilgun and other gadgets What is yours gonna eventually have in it.

I thought about metal but the cost & weight could be highly prohibitive. Bondo is very hard & not so heavy. As for gadgets - the only plan right now is the lighting & under the chest panel.

hi frnd, i had read ur comments jst nw. am karthik frm india tamilnadu state.. i finished mechnical engineering done an invention in hybrid.., nw i 'd lik to create a ironman suit jst lik a suit showed in movie...,
llu pls help me to build shall we join..,
it consists some electronic things, circuits, mechanical components, rocket propulsion, etc..,
jst mail me at jkkmethebest@gmail.com
call/msg me at 08012361561.

take me as ur frnd r brothr i really need help to build this

user

"metal but the cost & weight could be highly prohibitive." -again aluminum i see as the solution but then maybe i am misunderstanding what your trying to do with this i would build each piece individually and then attach to a joint like out of a knee restriction near the ear that way th face plate could coil up.

user

would there need to be a frame of some sort also the weight would not be so bad if aluminum were used i already started on a titanium model for serious protection i am often in a war zone or dangerous situation with my line of work and i would love to see an actual bullet proof face shield (with some vision) for some friends of mine

I've got to say, there are certain physical limitations with this idea. For one thing, this sort of protection simply won't hold up against anything except (maybe) small-arms fire, and even then at long range. The problem you face (no pun intended) is that most anything you use to protect your head in general isn't going to do anything but translate the force straight through. That's half the cause of injury from GSWs in the first place. Most bullets travel at about 1500 fps, so stopping bullets suddenly - well, that inertia has to go somewhere. Wearing a vest is one thing - it protects prom piercing (sometimes) and spreads some of the impact force out around the ribcage, but not all of it. That's where the bruising comes from. To do that for the head/face would be nearly impossible, due to the simple fact that there isn't a complex network of bones like the ribcage to spread the force around. It might not make a big mess piercing-wise, but it would still feel like getting hit in the head with a hammer. Now it might be possible to reinforce a faceplate with an underlying mask comprised of d30, but you'd still have to deal with whiplash and head trauma. That said, it might not do much for bullets, but I imagine it would go a long way towards preventing damage from the flying debris of IED's, but again not one that would go off right in front of (or beside) you. I would also like to point out that titanium is capable of withstanding great tensile strain, but is awful for high-speed impact. It tends to shatter unless its a certain thickness, 5 inches I believe. Yet another thing to point out would be vision field - You wouldn't have much at all. Transparent aluminum might work, but again we're talking about force having to go somewhere, and your eyes still wouldn't be very well protected.

hi frnd, i had read ur comments jst nw. am karthik frm india tamilnadu state.. i finished mechnical engineering done an invention in hybrid.., nw i 'd lik to create a ironman suit jst lik a suit showed in movie...,
llu pls help me to build shall we join..,
it consists some electronic things, circuits, mechanical components, rocket propulsion, etc..,
jst mail me at jkkmethebest@gmail.com
call/msg me at 08012361561.

take me as ur frnd r brothr i really need help to build this