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

 by hueezer
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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

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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

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

Tools:
Pen/Pencil
Scissors
Paint Brush
Glue Gun



eherrera5 says: Oct 3, 2012. 9:18 PM
Where did you buy the unitard, also can you but a picture of the vinyls and how you made the lights
Chillout says: Jun 5, 2012. 5:50 AM
Awesome!
do you have any patterns for the armor shapes?
bamf91891 says: Nov 11, 2010. 4:17 PM
Cool concept would love to see a more complete looking suit though. (ie. more red!)
hueezer (author) in reply to bamf91891Nov 16, 2010. 8:27 AM
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!
Jumpkick007 in reply to hueezerFeb 20, 2011. 2:58 AM
Where do you buy the vinyl ? I'm looking to make a better megaman costume than I did last year
hueezer (author) in reply to Jumpkick007Oct 24, 2011. 3:25 PM
I got the vinyl at http://mjtrends.com/. 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
Jumpkick007 in reply to hueezerOct 24, 2011. 11:34 PM
sweet what did you use on the helmet ? i need to get on done by saturday :-\
hueezer (author) in reply to Jumpkick007Oct 25, 2011. 11:19 AM
The helmet was also done using foam and vinyl.
bamf91891 in reply to hueezerNov 16, 2010. 9:38 AM
well I definitely love the way it looks, hope to see an update once you complete it!
onestooge says: Oct 17, 2011. 3:40 AM
How are the seams glowing?
Thanks
hueezer (author) in reply to onestoogeOct 24, 2011. 3:26 PM
For the seams, I used electro luminescent wire from www.thatscoolwire.com
mstyle183 says: Oct 24, 2011. 2:12 PM
agree!! where did you buy the vinyl? more infor about this would be nice
doombot9000 says: Mar 12, 2011. 6:20 PM
Love the fact that you used the comic suit, not the movie!!!
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