Instructables
A year ago I decided that I wanted to make the ultimate Halloween costume, so I decided to make an IRON MAN costume. I had no idea at the time how involved fabricating the suit would be. It was a challenge, but a lot of fun. If you are thinking about making a costume like this, you need to plan on spending 6 months to a year in order to achieve the desired results. Have fun with the whole process, you will learn a lot and have fun making a unique costume. 
 
Materials I used:

1. Foam EVA, Sheets from Sears
2. Hot glue gun, gluesticks
3. X-acto knife, replacement blades
4. Card Stock for patterns
5. L.E.D. pre wired lights from Radioshack
6. Two 9-volt batteries and battery clips
7. Old pair of shoes, and gloves
8. Foamies from Joann Fabrics for the hands and neck parts
9. Jewelry casting plastic bracelet mold form hobby lobby, and plastic resin
10. Copper wire for Arc reactor
11. Old water faucet head
12. Modge Podge
13. Plasti Dip
14. Red and gold spray paint
15. Velcro
16. Iron Man free downloadable costume patterns, Google pepakura files Iron Man
17. Permanent Markers
 
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Step 1: Step 1

Picture of Step 1
IRON MAN COSTUME 003.JPG
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IRON MAN COSTUME 199.JPG
IRON MAN COSTUME 202.JPG
I started with the Arc Reactor, I used a jewelry mold and plastic resin from Joann Fabrics for the body of the device, then I drilled holes and inserted pre-wired l.e.d.'s into it. I wrapped the ring in black foam and copper wire, used an old mason jar lid to hold it, and then attached a cardboard backing and glued an old faucet head in the center. I added large industrial staples for effect. I wired the lights to a 9 volt battery clip for power.
So how do you put it on? Do you just slip each piece on or do they break in half and reattach around your limb or what?
joetime (author)  DanielHolland29 days ago
I slip each piece on individually. There's about 12 or so pieces.
If I give you all of my measurements and such could I pay you to make me one??
joetime (author)  icekingschesthair5 months ago
If you would like to start a conversation about that, please email me at empire_1985@hotmail.com

Who's helmet file did you use? Your blueprints look alot different than what I have, alot cleaner actually. I've had issues with mine and have been looking for a smoother template. I can look up the pdo afterwards if you remember the the file name

joetime (author)  beastmodecuban5 months ago
I can't remember, I found it on therpf.com
clonestranger7 months ago
How much did it cost?
joetime (author)  clonestranger5 months ago
about $300
itri456 months ago

Very Very Impressive. I'm hoping to start a MK42 version soon. The only thing I have a question about is did you prime with Modge Podge, then PlastiDip and then Paint. Or is it just one or the other?

jackson98828 months ago
it looks so easy and awesome
jjoseph109 months ago
Can you please post the exact pep files you used for the foam build? It would help out a lot for others trying to follow your steps!
sokiboi789 months ago
Nice job.!!.GO IRON MAN!!
check out mine what u think? made out of card boards and tape lol Vote if you like ;-)
jharley9 months ago
Hey Joe,

I gotta say very very awesome job. Really love the eyes and the helmet. Everything actually. I noticed you don't have the hand plasma lasers..Any reason you left those out?

Thanks so much for sharing this. Amazing job!
joetime (author)  jharley9 months ago
The reason I left those out was due to time...just didn't have enough to make the palm lights, but I will probably add those in the near future.
softblubber9 months ago
How did you make the angled cuts so nice (for example, when two pieces come together at 90-ish degrees)?
joetime (author)  softblubber9 months ago
When I was making the angled cuts at 90 degrees I used a bevelled x-acto knife ($4 at wal-mart). It makes 45 degree cuts, and I would cut both edges at 45 degrees so when they were joined together, I would have a clean 90 degree edge .
BigStoddy9 months ago
Nice work. I wonder if a clear coat over your final paint would let you wax and shine it.
joetime (author)  BigStoddy9 months ago
Good Point, I'll consider doing that. Thanks
mommyhen429 months ago
Awesome!! But how do you see out of it?
joetime (author)  mommyhen429 months ago
Check out Step 4!
rsucgang9 months ago
Fantastic! I'm thinking of doing the same thing for Halloween next year. Thanks for the inspiration and the instructabl. Well done!
sircorvus9 months ago
Wow, really great!
how much time did it took for it and yeah I voted for it
joetime (author)  Andrew Garfield10 months ago
I took my time with the costume, it was a fun hobby. I probably put in 4-5 hours per week for about 9 months. Whenever I had the time to work on it I took advantage.
boras10 months ago
Nice work but I still dont get it why to waste time on foam when u can do it hard way with better effect ( paper +fiberglass)
joetime (author)  boras10 months ago
I've never worked with fiberglass before, so cutting out foam and gluing it seemed a lot easier.
boras joetime10 months ago
Yea i can agree with that foam is much easier. but paper would give you better more detailed results. Myself i made a helmet out of paper+ fiberglass still need to put a bondo filler on it but having to much work not allowing me to do what i enjoy :/ anyway like i said :) well done :)
HrdWodFlor10 months ago
Very nice! You did a great job on this!
joetime (author)  HrdWodFlor10 months ago
Thanks!