Instructables

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.
 
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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.
Maverick275 years ago
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.
blackpualani (author)  Maverick275 years ago
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
"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.
bame5 years ago
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
yea, I saw this movie on the big screen, and after while just yesterday, I thought to myself and asked my friends do you think it is posable to make the real suit? but all they said was "it isn't posable with our knowlege" & all i said i think it is it just takes more time, work, patience, and testing. I started a design and the paint, i'm only 16 but after i finish high school i will start college after school, then get a job get the cash i need, the main problems I am haveing trouble with, is the power source, the flight stabilizer, the hover system, and flight thrusters, the navigation system and more but that is all i will name for now. please comment if you wish.
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
I figurd the stabalizers & thrusters cud be air, suckd in constantly, so no stor up, the lasers r just high wattage, lik, mager wattage, power not so easy, but im lookin tat up now, so, ill keep u postid ;) im 12, & i don't no if that wud work or not, if it wud, y am i the only 1 to figure it out?
You simply can't make a pump powerfull. The lasers would need a hundred nuclear power plant to run, an di seriously doubt you'll get anywhere near those.
I am not so experienced, but the energy could come from an alloy I'm experimentimg with. has highenergy storage. I feel really stupid right now though:P
Experimenting with an alloy that somehow produces energy? Good luck with the radiation poisoning.
haha! I'm sure that a lot of people would happy
WHAT OTHER THINGS U HAD TROUBLE WITH BEACUSE I WOULD LIKE TO KNOW
I HAVE TROUBLE TURNING CAPSLOCK OFF
I'm 15 and though it was an awesome idea to make the suit aswell. I've found a way to lift my weight and 30kg extra, for the suit weapons etc. I to am looking for a pulsar system, but it is only under testing in america. it isn't a hover system either as this would create to much heat under the suit( may burn the ground). the main problem i am having is the flight. comment if you can solve my problems.
thanks

J-dog
Lies
Yes there is you just haven't tested anything with it
I test your lies.

I've got the thruster, stabilizer, and basic power source dwn for my suit. It would be cool to see how others turn out, but for now I'll keep going on mine.
All physically impossible.
Don't try to make a fully functioning suit, just make a prop. There isn't a power source small and powerful enough to run it.
Do this, and then plug in your lazorz , pulse beams, LEDs and thrusters into the other outlets.

Problemz?
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if scientists can't build it personally i dnt think you can unless of course you are only building a prop....
im making a ironman suit well actully a war machine suit do you know where i can get some missles
Missiles may be a little harder than anyone may think to get. Consider this, most of the weapons will be off limits to civilians. So you either have to custom make your weapons or some other option. The other 4 friends of mine and I are going to open a weapons manufacturing industry to create a new wave of weapons that will change the history of war. For example: A Missile that has a built in computer granting access to only those who have authorization. Security system will include, Eye or Retinal Scanner, Hand Print Id, and specific codes, maybe even some voice activation as well, and all of this will be one big security system to make sure that the weapons do not fall into the wrong hands. I am thinking of a bomb that we currently use in war and modifying it so that when all or to many attempts at the security goes wrong the missile will have a default and will have all these different things happen within it that will make it non-fissionable or not able to blow up or be used for nuclear purposes. So just think about it. My Email is below this comment on another comment lol. or here -> cdthomas93@yahoo.com Thanks for reading.
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
Ask your neighbours.
I have my suit model with the metal and everything placed i need a energy source now the arc is a source that would work but tony didnt give out his big secret of what he made this power from. I have tested the suits capabilty of Blocking bullets i ahve to work on the head the body aromor is done. If i can find the power source navigation system andhover system i got it all out. My flight stabilizer wasnt easy to get i must say. Now, if any of you need help with the suits layout and blueprints i can help.
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
And for those that are already building it think. Use Titanium for all or most of the inside frame but the outside metal was an alloy. An alloy is when you take two metals and combine them. Using a "Gold-Titanium Alloy" like what Tony uses in the movie was a very good point for several reasons. For one Gold unlike normal matter or metal does not expand when heated or contract when cold, but will how ever melt under EXTREME and I mean EXTREME temperatures. He combines Gold with Titanium to produce a sturdy alloy that can keep all of the suit intact and protect him from fire arms. The "Gold-Titanium Alloy" used in our space satellites does not freeze in space like normal metal which is why he used to so he could fly to high altitudes without the suit freezing up. Also the hand and foot repulsors are produced from plasma. I am not entirely sure on what materials to use to produce plasma but because the real arc reactor is made from radioactive materials I figure that some how you could reroute partial power from the reactor before the radioactive materials are converted into electricity to power the suit. Also you might want to take radiation poison or sickness into consideration. Remember this. In order from short wave to long wave and not bad to worse: Alpha-Blocked by paper and outer layer of skin/ Beta-Blocked by Plastic/ Bremsstrahlung-Blocked by Plexiglas/ Gamma and X-Ray-Blocked by Lead/) Now all of these can be blocked by lead so that is just something to consider if you don't want to use so many materials to block radiation but remember the result is cancer for all of them or worse so CAUTION! Thanks for reading.
The most scientificakky accurate comment ive read so far.
the radiation poisoning was why he created the new arc reactor in iron man 2.
tinker2342 years ago
where ccna i get mark 1 armor for pepurka
Qtrowl3 years ago
The eyes are to big
mva134 years ago
hey. i love ironman and i want make a costume buth its not going so good.
i need a mold ore something

mark.
GMer564 years ago
Mask seems a little wide... great job though!
will be interested to see when this it is done.....
blackpualani (author)  explosivemaker5 years ago
You & me both brother
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