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:
Paper Cardstock
Hot Glue
Your PC and Printer
Pepakura Viewer software

DOWNLOAD Pepakura software.

DOWNLOAD Pepakura files.



(Updated on JUN 12, 2012)
Thanks to ROBO for this awesome files!!! the best 3D model of ironman on the web!

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Step 1: "Print - cut - Paste"

Picture of
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.
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digg44443 years ago
I downloaded the pepakura... the right shin left shin r the same! same thing w/ the right/left handplate...any suggestions?
same w/ shoulders, thighs and biceps
sekkei (author)  digg44442 years ago
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.
senshidojo6 days ago

love it!!!

I'm in the process of building the Mark IV using your process and I noticed that there is some sort of under armor under the chest and under the back piece. Is this the collar plate? as it looks to be one piece. Or is it something else?

Can you help? Thanks

DayatS11 month ago

I have just downloaded the files. Thank you so much for sharing this :)

ola amigo bom dia, adorei o trabalho, mas não consegui baixar em pdf, poderia enviar o projeto em pdf para meu e-mail: obrigado bom dia.

AndreR11 month ago

this is awesome! best one shown on instructables.i definitely wan't to make one like the way how would you light up the eyes?

oud253 years ago
where did u get the PEPAKURA file?
CATP12 oud251 month ago

The pepakura file is on the first page of this Instructable. Copy and past the link given and you will come to a page that you can download the parts. If you need Pepakura Veiwer or Designer, go to this link:

wraith1091 month ago

I would like to use this method on another project, and I am curious, can I use fiberglass resin on poster board foam?

ChrisReezy71 month ago

is the cardstock paper you used white or what color?

It looks like he used white but that isn't a big deal because it will be covered with body filler and paint.

trinity951 month ago

hey i am having troubles downloading the files i got the shins and thighs and spine but everything else is an empty file folder but the shins, thighs, and spine are all pdo files any idea why its doing this?

dhaughewald2 months ago

How tall are you? How important would body type customizations be in your opinion? I'm currently about 5'9" or so, would you suggest any major changes for my build?

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BuckmasterAR2 months ago

like me get this straight, you are able to fit inside of it right, b/c when I looked inside of the helmet file, it seems to be reinforced across the inside towards the front, is this correct.

zache2 months ago

Hello. I have a question for the author who made this suit. I have a person claiming these pictures as his own. His name is Brad Evans and he lives in TN. He is wanting to trade for this suit he claims to have made but the images he texted are these above. I am wondering if this is a scam because I always do my homework before hand. Please let me know ASAP!!!! Thank you so much. PS This suit is amazing to whoever did actually make it. Thanks again!

sekkei (author)  zache2 months ago
Hello, sure is scam, as far as I know the new owners of both of my suits they still have them, one suit is in California and the last and second one is in New York, and the name you gave to me doesn't match any of the actual owners.
Beware and thanks!
md40312 months ago

I am 5'7, 172 lbs. What scale should I make it in the software before printing?

Also, what do you use for a foundation or support when gluing the pieces together to ensure accuracy?

zonmin3 months ago

sekkei, please help me. i don't know were can i find the link for the iron man whole suit. also, do you have the mark 3? i think it looks better :-)

A1IT3R4 months ago

what size are the feet? ;o

jakub.kis.354 months ago

how much did it costed you to make the armor?

jakub.kis.354 months ago

i live in poland and i don't know can i get all of the materials. can i do this somehow else? :/

Tgizzo6 months ago
props to you man! I tried this method, and I only did the helmet. The rest was just too much time, money, and glued and burned fingers! I'm moving to the foam method for the suit now. Congrats bro. That's dedication ;)
wakkowolf126 months ago

Making Marvel movie good design how do you make the Helmet move?

CommonName6 months ago

So I'm a wee bit short (5'4 to be exact) and I wanted to know if I make this suit will it fit and how much did this cost roughly

ajatmiko7 months ago

Pepakura files Empty Folder???

rgillis1 ajatmiko7 months ago
Have you found the files yet? I'm looking to. All I can find are the mark IV, but I want the VI
takitty0077 months ago

Hey, your link to the pdo files goes to an empty folder. I was just in it a week ago and it had everything but I didn't save them. Have they been moved? Do you still have a copy of them??

Have you found the files yet? I'm looking for them to.
rgillis17 months ago
The folder is empty to the pep files. Can you help please?
macmice7 months ago

ive had my eye on this for a while now and was wondering if you could make me a suit and have it to toronto by the summer? if not half way thru it? could you email me the price and info?

Green X7 months ago


stsiganis8 months ago

can you give us the patterns? That would be awesome

Bryant889 months ago

One more question, On the faceplate, there were some pieces one the pepakura viewer that would not print. they were the pieces around the eyes, and i cant figure it out. Are they necessary?

abedre9 months ago
please help me tell me which dremel tools u used for it
maron6131 year ago
do you think ill be able to finish in 20 day?


sorry if the reply s late =P

if all 20 days are free and if you can work all day then yes

sekkei (author)  maron6131 year ago
jbushehri9 months ago

found a summer project

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