IRONMAN 2 suit (mark 6)

Here's the DIY of IRONMAN 2!
This is my first experience doing something like this and I want to share it, 4 long months working all weekends. This is the pepakura method, so you need a lot of patience.
 
"Get ready for..."  Stage

 First list of material:
Scisors
Knife
Paper Cardstock
Hot Glue
Your PC and Printer
Pepakura Viewer software


DOWNLOAD Pepakura software.
http://www.tamasoft.co.jp/pepakura-en/

DOWNLOAD Pepakura files.

https://rapidshare.com/files/1830044798/IRONAMN_Instructables_Folder__SIZE_Letter_SCALE_26.27_.zip

(Updated on April 29, 2012)
Thanks to ROBO for this awesome files!!! the best 3D model of ironman on the web!

Step 1 "Print - cut - Paste"

Once you have all the files in your PC, you proceed to print each part.

Cutting the pieces by the solid line.

The dotted line is for "mountain" folding and the dot-line-dot is for "valley" folding.

Match each tab with its corresponding number using hot glue, helped with the Pepakura Viewer to identify easily each piece.

Do the same with all the parts one by one to avoid confusing the pieces.

TIP: Save each printed & cutted page of the part in numbered folders for easy identifying.

Comments

[digg4444]

I downloaded the pepakura... the right shin left shin r the same! same thing w/ the right/left handplate...any suggestions?

[digg4444]

same w/ shoulders, thighs and biceps

[sekkei]

HEY! Sorry for the delay...
Here's a thing! some pieces are the same in the 3D model (left and right),
but if you take a look closely they are not the same, try to print them and you will notice the difference, I really have not idea why the 3D model doesn't change when flip is apply to parts.
Other pieces, like the hand plate, are just the same for both sides.

[ironman 2]

I have a question........ which pepakura software do you have to get?

[sekkei]

You can use Pepakura Designer or Pepakura viewer, either it's Ok, but the Viewer is free. You can find them in the link from the first step

[Theshowstopper_799]

can you adjust the size of everything in pepakura viewer?

[Opt!mus Pr!me]

Hey can u tell me what sinze the costume has....
thx

[sekkei]

hummm.. that's a complicated question, it depends on the part of the suit.
But if you download the parts and the pepakura software, you can check the size of each part in milimeters!

[Theshowstopper_799]

How, I downloaded the Pepakura Viewer can it be changed through that? Awesome job man! Thanks in advance

[Hitori Hanzo]

How tall are you / what do you weigh? (That should indicate if the costume would fit me as printed)

Thanks

[ksian1]

is the pepekura file is free?

[murriano]

I plan on making just the helmet. What would you recommend as an alternative to the fiberglass (which I'm assuming is the largest bulk of the cost) where I'd also be able to use body filler to smooth it out?

[FJK-Possimpible]

I have three questions:

1) How much did you spend on the whole costume?

2) Did you use just normal printing paper for the first step?

3) In the "Fiberglassing" step, is the paper strong enough to keep its shape when you put fiberglass on it?

[sekkei]

1) Not sure really but I think around 500 bucks
2) Is not normal paper, is that paper that is used for presentation cards.
3) It is strong enough =)

[FJK-Possimpible]

is there any way that i could leave the body filler step away, or would it look dodgy or would it be not strong enough or something?

your costume looks awesome, can you open the mask on your helmet?

[FJK-Possimpible]

wait a second, will it even fit me? im about 1,78m ...
:D

[Muncer92]

Do you print it on A4 or A3 paper?

[denniz]

Very cool tutorial. started today to make my own costume :) cant wait to see my first part irl . but I can agree with the others: legs and shoe templates are missing, would be so nice if you upload them :)

greetings from germany ^.^;

[sekkei]

Link updated!

[btp834]

Hey!
I downloaded the files and it seems as if everything from torso down is missing. Any new links for these missing files? :S

[sekkei]

Link updated!

[denniz]

please add leg + shoe models, cant wait for them u.u

[sekkei]

Link updated!

[renaldo30]

hello

i downloaded the pepakura files .
but i am missing the hands but on the foto i see hands .
is this file missing . my email is [e-mail].

please send me the hands.pdo i really want to build this

greetzz rene hof from holland

[sekkei]

Link updated!

[Mikeh1994]

Awesome work on this! I can't wait to try to build it myself. Unfortunately, I've got the same problem as a few people in that the file doesn't have any of the parts for the legs or feet. It's only got the torso, arms and helmet files. Is it possible for you to reupload the file with all the parts?

[sekkei]

Link updated!

[origamidude99]

how could one scale it for a bigger person? im 6 foot 1 and a little husky

[McChicken]

How the hell did this only get third place? I thought it would win easily.

[gcarpino1]

what is the size of person the costume will fit? head measurement, chest, waist, thigh?

I am 5'11'' 200lbs fit build, 73/8 hat size any ideas. can this costume be tailored for different size individuals???

[rcmaster]

Hey love the suit but im having trouble with the downloading process so if you could send me some more information about that it would be great.

[inventingdude]

I downloaded the pepakura files and the software but there are some missing pieces like the legs and boots ... if you can help it would be great ! :)

[Anthony E. Stark]

Hey Sekkei,
first of all i want to say what an awesome job you did there. I'm really looking forward to trying this myself someday.
Just out of curiosity: I downloaded the viewer and the files via rapidshare, but i seems, that there are still a few missing.
I read in the comments, that you updated the file several times, so is there any adress i could get the complete package? As far as i can see, most parts from torso downwards are missing.
Thx in advance

Just decided to list the items contained in the rapidshare zip folder (IronManSuit_SCALE_26.27)
Folders: Biceps, Forearm, IM_Supports, Shoulder L,R
Files: abs, back, chest6, codpiece, collar plate, complete, handplate, hip pod, mk6 brace, neckseal, helmet, spine

[fidelisepsna]

How much does the finished project weigh? I'm planning a similar project but I'm afraid that fiberglass would be too heavy to wear.

[greyhuk]

I have seen on other sites it is about 10-12 pounds based on wether or not you use bondo for extra detail or extra perks like wireing and lights. There is a guy who made a movie correct War machine. He used aluminium and an airsoft machine gun for the gattling gun. I think he said it was 40lbs....

[HellsHarlock]

fiberglass is actually pretty light, no heavier than most sports gear really.

[InsaneWrath]

I am working on a full metal set and have a tazer gauntlet and flamethrower gauntlet for each hand but I am dealing with weight issues (Ican can benchpress 2 people and its still somewhat heavy

[greyhuk]

Sorry ment to add it would save ALOT of weight.

[greyhuk]

You can try Kydex, and aluminium. Kidex is a heat moldable ballistic grade material. Its the same stuff they use for the hard style plastic holsers or the nonmetalic knives.

[therimmer96]

nice costume. thinking of doing this. but two things, why when i got rapid share and downlaod the file do i get a .cgi that nothing can open? and second, how well can you see out of this?