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
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
Step 2: Make the Pattern
Tools: Pen/Pencil, Scissors
This step may be the most simple and straight forward, but its the most important step. Spend time to perfect your pattern. One starting point is to use a many good reference pictures of ironman. You can use Photoshop or any photo editing program to resize the images to life size. This is a good starting point for your patterns. Don't be afraid to mess up, construction paper is cheap!