Picture of Iron Man DIY
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.
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ElphabaT1 month ago

Where did you get the templates?

Dany23456 months ago

Thank you. Found it helpfull.

which arc reactor tutorial

TN7771 year ago
If I ever go to Knoxville comic con, this is what I wear!
Freakin' awesome!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
AJC8891 year ago
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!
avenger221 year ago
Thank you. I find you useful.
LULLI2 years ago
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!!!!!
burao2 years ago
Do you make other armors like mark 4,5,6,7 or is that the only one you use?
Cool!!! Your costume has been very inspirational. I might even make my own.
can you make a batman costume to?
yusuf7864 years ago
Hey Cool Suit. Any Weapons Attached ?
doombot90004 years ago
Wow! Nice job!
zinnatty4 years ago
when it's green & purple looks like buzz lightyear's suit lol
thepelton4 years ago
Did I notice that your ears are visible from the back?  There was complete coverage in the film, otherwise he would not be able to fly into subspace.
eseidel (author)  thepelton4 years ago
Did you also notice that my body is sticking out as the suit doesn't fully enclosing me.  There was complete coverage in the film too otherwise he would freeze to death in that atmosphere. It also wasn't bolted together over me if you were wondering that too.
Is it possible that you could draw out a template for each piece of the torso? Thatd be awesome if you could :D
eseidel (author)  firefreak20074 years ago
The pictures of the torso in the slideshow would be the template as I didn't have one to go on. 
zach willis4 years ago
dude frecken awsome can you make a instructabul on it
eseidel (author)  zach willis4 years ago
Thanks.  Sorry but there will be no instructable for this. 
Too bad, I really wanted to make one for my little brother.
eseidel (author)  DarkerStitches4 years ago
 Yeah sorry.  I just don't have that kind of free time to redo it or document it.  If you follow the pictures though I'm sure you could try.  If you have questions you may message me and I'll try to help.
zach willis4 years ago
duelist4 years ago
Hey NICE suit I have a question though...
With the chest plate is it sheets glued together, one on top to make the basic shape???

This could really help me.
Also could u send me pics of your templates?
Email is if not just say so, (I know that there are no plans etc.)
moniter man5 years ago
(removed by author or community request)
eseidel (author)  moniter man5 years ago
Thanks, I knew the head was a little mishapen but I didn't have time to redo it(finished it day of halloween). However, now that I have more time I plan on correcting the helmet. Im also going to reduce the shoulders a little bit and a few other things. Torso was one of the most difficult pieces for me as well. Got any pics of it? War machine does sound like a really good idea though. I'll have to think about that one.
i used some foam to make the helmet by using a papercraft model(which i cut apart) and glued together with hot glue and pieces of cardstock, now i just need to patch it up, and it will look great, i will soon, just as soon as i find my camera;D
you reakon it would be possible to blow a papercraft model up to humansize, stick on card then harden up, sanding, painting etc?? :D
i need an email address so i can send u the pics ;(
piratelord45 years ago
Quick Question how much  money would it take to have just whats in picture 3 from the right made. generally just the chest piece and connecting back. I wouldnt need it painted.
eseidel (author)  piratelord45 years ago
To do it yourself will cost you around $20 for the chest piece.  I can't help you though because it was all trial and error as I went.  No measurements.  Took a while though to get it to look right.  Good luck. 
good job! it's cool but shoulders are too big, mak them smaller and the suit will be perfect.
eseidel (author)  DracoMorgendorffer5 years ago
I agree completely.
moniter man5 years ago
hey, it's me. i made my warmachine/ stealth armor iron man suit, and it was a great success, i will try to send you the piks :P 
eseidel (author) 5 years ago
With Halloween coming up, I am getting more and more e-mails asking for instructions and blueprints. PLEASE READ the description and comments and you will see there are none. It was all trial and error and lots of patience. I will ignore any e-mails that ask for instructions so please don't bother. If you have questions that's another thing but I DON'T have instructions and I DON'T plan on making any for this took long enough as is to make. Maybe future projects will but not this one.
Could you send me directions here is my email
eseidel (author)  Ultra Computers5 years ago
NO, there are none other than the description I wrote which also states there are no directions.
PyroMonger5 years ago
one do you go to the bathroom with that thing on? Now there's a challenge lol
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