Introduction: IRONMAN MKVI Suit (in Progress)

Picture of IRONMAN MKVI Suit (in Progress)

After Making a rushed arc reactor i desided that i must make a full Iron man costume. Unfortunatly i dont think it will be done before Hallowen due to being at school but stay posted for all the updates as they come. I have only ever done fiberglassing when building a canoe.

The canoe was much easyier as you just lay down strips on the joints of the wood, but the intericut detail of this project is completly differnt to anything like that.

So be advised THIS REQUIRES A LOT OF PATIENCE!! The Suit this Instructable is about is the mark 6 from the well known Ironman 2 film and it is also seen in the first half of The Avengers. The inspiration has come from Instructables member Sekkei. Many of you may have seen the foam Suits but this is a Pepakura version which is a lot more time consuming. 

Step 1: Pepakura (Printing, Cutting and Glueing)

Picture of Pepakura (Printing, Cutting and Glueing)


-Pepakura viewer software
-The pepakura files or (
-glue(pritt stick)
-scapol/craft knife
-Thick paper
-A printer

Pepakura is a 3D modelling program which enables a user to take a 3D design and 'unfold' it, like it was a paper cut out. so for you all you have to do is to print it and cut all the pieces out then glue them together. i suggest using a polysleve to keep all the piece of one part together at a time so you don't loose them! you need to be printing onto thick paper or paper stock. I got mine of Amazon but the UK site doesn't have much choice at all so browse the internet for some. 

Once you've printed all of the parts keep them ordered otherwise you wont be able to do it! cut them by the solid black line and use the craft knife to indent the fold areas(dotted or dashed lines). Dotted lines should be bent away from you and dash/dot lines towards you.

Using the Pepakura viewer link and glue all the pieces together to create the part of the model. There are LOADS!!!

Step 2: Fibre Glassing

Picture of Fibre Glassing

Fibre glassing is a time consuming progress! it could possibly take longer than the cutting and sticking. It requires a few safety points as the resin produces dangerous fumes and the fibre glass mat can get stuck under you skin and cause serious irritation.

So.... the Kit:

-Disposable gloves(loads of them)
-a Respirator

All of the above can be bought at a local DIY shop(I went to B&Q)

-Fibreglass matt
-resin with its hardener(they are normally sold as a pair)
-A Dremel tool with multiple heads
-tin foil( aluminium foil)
-WD40( spray lubricant)

To start with prepare a work area that has little dust and lots of ventilation. outside is fine as long as its not raining. prepare the work bench or table by layering it with tin foil using the cello-tape to hold it on. do this to a few boards as well so you can put things to the side to dry etc. spray each one with a good dose of WD40 to stop any resin from sticking to the foil.

Cut all of the fibreglass matt into pieces big and small, medium and odd shaped. you will not know how much you need so do it all. cut this with scissors and gloves. put on you overall and goggles as well as your respirator and begin mixing the resin with its hardener. different brands have differnt requirements on ratio so read the box to check. i used about 1;5. layer the inside of the part with resin and cover it with fibreglass after this add another layer of resin. Depending on how big the part is it may need another layer of fibreglass other wise it will be too flimsy. just do the same as above on top. after all the coats are on and a little bit solid, paint the outside of the part with resin as well, ONLY RESIN.

Leave all the pieces to dry for a day and they will be rock solid. I found that the chest and other large pieces didn't stay in shape whilst the stuff was drying so I held them until they had dried stiff enough to stay in place( 5 minutes)

Repeat the process on all of the parts, still in progress for me :(

Step 3: Body Filling(coming Soon....)


parmejahn (author)2015-06-24

requesting pep files for the helmet please!! .. john

julia1923 (author)2015-06-17

can you please send the pep for the helmet to

Super Rohit (author)2015-06-14

Please send files to

miress (author)2015-05-28

Can you pls send files to my mail? thx

VojtaJ (author)2015-04-18

Can you please send the files to my e-mail? ( ) Download links are not working.

angel hernandez (author)2015-04-06

Can u still send files....if yes can u send it to

AnujS3 (author)2015-04-05

can u send it to

Aaronh8 (author)2015-03-28

please send to

roshkowebrat (author)2015-03-16

please can you send files to email

adam.haley.927 (author)2014-11-01

Can you please send the files to me at I'd appreciate it.

dhaughewald (author)2014-10-08

Could you send the files to I'd really appreciate it. My school has a few laser cutters and 3D printers so I'd like to try and make one in the lab.

GauravG (author)2014-09-20

can you send all suit files and pdf file my email

PirateBrown (author)2014-01-14

Would you be able to send me the pep files as the link for the peps don't work no more

rgillis1 (author)PirateBrown2014-05-22

Hey would you be able to send them to me to please I'm looking for Mark VI.
Thank you

Alex Jalland (author)PirateBrown2014-01-21

Just sent them, please check your mail

rgillis1 (author)Alex Jalland2014-05-22

Hey would you be able to send them to me to please I'm looking for Mark VI.
Thank you

legocreator2 (author)2014-01-21

What paper do you use?

Alex Jalland (author)2014-01-21

Just sent them, please check your mail!

Thank you!

Alex Jalland (author)2013-11-25

For all of the people following my page to see this finished, it is temporarily on hold as the resin/filler does not set in the cold and the shed I am making it in does not have heating :(

Alex Jalland (author)2013-11-25

For all of the people following my page to see this finished, it is temporarily on hold as the resin/filler does not set in the cold and the shed I am making it in does not have heating :(

mallen36 (author)2013-11-24

Anyway you can send me the pep files for the entire suit captmimo22@ bed thanks I follow you to see how it finished out I'm half way through a Halo suit ATM lol

Alex Jalland (author)mallen362013-11-25

I have attached and sent them to you via email.

Robine007hawk (author)2013-09-26

what are dimensions of your helmet and what settings i should choose???? please help me out

astral_mage (author)2013-09-14

umm the links are broken 4 wat ever reason

sbhave1 (author)2013-07-30

Sorry, another question, how much fibreglass mat was needed for the helmet? I saw a kit quite similar to yours and they had a mat which is 25 cm by 110 cm. Is that enough? I am just doing the helmet first before I even even cut out the other parts to get a feel for things to come.

Alex Jalland (author)sbhave12013-07-31

For the helmet this is about right as you will not need two layers due to its spherical shape. Structurally and all it holds very firm with one layer.

sbhave1 (author)2013-04-14

Very helpful tutorial! :D
I as wondering how exactly you joined the card stock once printed out? Some of the parts I printed out for the helmet seems incredibly thin and the numbers overlapped so much so it was hard to identify which numbers they actually were

Alex Jalland (author)sbhave12013-04-14

Good question! I have just updated the paper assembly step with a picture of the helmet. I have just finished it. I use pritt stick(a glue stick) as I do not have a glue gun. It saves my from getting burnt and it holds very well. Some pieces are very thin and fiddly but you just have to be extra careful with them. They may snap so be patient. Identifying them can be difficult to, use the pepakura program to guide you.

Crimson-Deity (author)2013-04-11

When is the next step comming up? =)

Hopefully this summer, sorry for the wait. That will be covering the fibre glass to make it detailed and ready for painting etc.

7uty56 (author)2012-10-06

Please build one for me!!!!!! im 5 foot 8

Alex Jalland (author)7uty562012-11-11

You could probably wear the same one as i'm around six foot and its looks like its going to fit

Alex Jalland (author)7uty562012-10-07

Dude, I would make loads if I had a 3D printer and Laser cutter, instead its all by hand which takes ages. :(

About This Instructable




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