How to make an Ironman Costume using the vinyl and foam method!

Picture of How to make an Ironman Costume using the vinyl and foam method!
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!
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Step 1: Overview, Materials, and Tools

Picture of 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

Construction Paper
Masking Tape
Fun Foam
Weldwood Contact Cement
3M Super 77 Spray Adhesive
Loctite Super Glue

Paint Brush
Glue Gun

Step 2: Make the Pattern

Picture of Make the Pattern
Materials: Construction Paper, Masking Tape
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! 
can you tell me please from which website you got the helmet paterns
Poho1231 month ago

Best one I could find

Sorry probably a dumb question but how did you add the glowing strips to the suit?

Also what are the glowing strips?

Thank you

doombot90004 years ago
Love the fact that you used the comic suit, not the movie!!!


Why does it light up
can you provide the template for the helmet?
eherrera52 years ago
Where did you buy the unitard, also can you but a picture of the vinyls and how you made the lights
Chillout2 years ago
do you have any patterns for the armor shapes?
bamf918914 years ago
Cool concept would love to see a more complete looking suit though. (ie. more red!)
hueezer (author)  bamf918914 years ago
Yeah, this isn't a complete suit. I had to finish what I could in time for the Halloween weekend. I was literally working until the last minute but one of these days I'll fully complete it!
Where do you buy the vinyl ? I'm looking to make a better megaman costume than I did last year
hueezer (author)  Jumpkick0073 years ago
I got the vinyl at They have a very nice metallic "wine" colored vinyl. Its the perfect color! I've actually done a megaman costume, but not in vinyl. Maybe one day I'll build a better one
sweet what did you use on the helmet ? i need to get on done by saturday :-\
hueezer (author)  Jumpkick0073 years ago
The helmet was also done using foam and vinyl.
well I definitely love the way it looks, hope to see an update once you complete it!
onestooge3 years ago
How are the seams glowing?
hueezer (author)  onestooge3 years ago
For the seams, I used electro luminescent wire from
mstyle1833 years ago
agree!! where did you buy the vinyl? more infor about this would be nice