I spent many nights lying awake trying to figure out how to make a man-shaped model rocket flight-stable, how and what to make him out of (to keep the weight down), how to construct the parachute deployment system, how to mount him onto a launch rod, what kind of launcher I would have to make, and on and on. I resolved most of the issues, and I'll show you how all of these ideas came together.
There were plenty of missteps and failures along the way throughout this project, but I've cut most of that out in order to keep this as straight-forward as possible. Please excuse the shoddiness of the exterior details on the finished rocket. This is less about the actual Iron Man character, and more about my journey and the process of trying to make and fly a crazy man-shaped rocket. In the end, you'll see that I had mixed results with this project.
I began by making the head, which I figured would be the hardest part. You can see the details of that here.