There are quite a few Ironman costume tutorials out there, but most of them require sculpting, molding or Paperaku. All these require sanding down your costume and painting it. We all know Ironman has an awesome metallic red finish but that's pretty much impossible to recreate unless you can afford to coat your costume with automotive paint.
The vinyl and foam method is much more DIY friendly...its flexible and gives you that great metallic look! This instructable will show you this process, and also other cool cheap ways to make your costume look awesome!
Step 1: Overview, Materials, and Tools
Making the armor pieces
Step 1: Make pattern
Step 2: Cut the foam
Step 3: Cut the vinyl
Step 4: Mount the foam onto the vinyl
Step 5: Glue the pieces together
Step 6: Making the full suit come together
Step 7: Finishing touches
Weldwood Contact Cement
3M Super 77 Spray Adhesive
Loctite Super Glue