Iron Man DIY





Introduction: Iron Man DIY

DIY Halloween Contest

Second Prize in the
DIY Halloween Contest

This Mark 3 Iron Man costume is very accurate to the movie's. I spent lots of time trying to get all the details in. It is mainly made of Poster Board, Foamies (arts & crafts thin foam sheets), a ton of Hot Glue(I think I used 140 sticks or so including the helmet and arc reactor), Mod Podge, and newspaper to thicken and seal the posterboard with Mod Podge. Mod Podge was also used to seal the foam to make painting easier. The entire construction of the costume took about 1 month on and off or 100 hours of labor. Most of the time was spent test fitting and cutting templates that fit me correctly.

The Arc Reactor was made by following the instructables Arc Reactor DIY using surface mount LED's and molding plastic.

The Helmet took about 40 hours of work (including drying,sanding,bondo, and painting). It was made by first creating a mold of my head as the base using Plaster Bandages you can get from arts and crafts store (Plast'r Craft is the brand). Once this dried I built up the Iron Man Mark 3 shape by using a very thin aluminum mesh(held down by hot glue) you can get from arts and crafts stores as well near the clays. Once you think you have the shape down, lay down more plaster bandages. If it doesnt look right like my first attempt(no chin) then repeat process with more mesh and bandages. Then, cover the outside of the helmet with bondo in small increments, sanding in between each application to a smooth finish. After that is just painting.

Painting was done using a Gloss Colonial Red and a RustProof Metallic Gold. I used lots of taping to make sure the colors didnt mix at all. Good luck its a lot of work but will be the talk of all the parties.



    • Pocket-Sized Contest

      Pocket-Sized Contest
    • Pro Tips Challenge

      Pro Tips Challenge
    • Science of Cooking

      Science of Cooking

    We have a be nice policy.
    Please be positive and constructive.




    Where did you get the templates?

    Thank you. Found it helpfull.

    If I ever go to Knoxville comic con, this is what I wear!

    Freakin' awesome!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


    Ummmmm can you or someone please send me pictures of the unfolded leg pieces because i cant seem to figure out the shin piece and I need a better picture of the thigh. THANK YOU SO MUCH IF YOU CAN!

    Thank you. I find you useful.


    Its pretty cool. you got a considerable amount of detail on there
    you made the mouth/cheek too wide and the resst of the helmet to round
    besides that its really good
    im hoping to make a mk 1 out of thicker/more foam
    and the armor just out of the poster stuff in tonys room in avengers
    oh and if you didnt know... I AM SOOOOOOOO MAKING THIS!!!!!