Iron Man Suit





Introduction: Iron Man Suit

My second costume build attempt using foam flooring from home depot.

Step 1: Starting the Foam Process...

I began by downloading files from the web, using pepakura software as my designer/viewer program. From here, its print, cut, trace, repeat.

Step 2: Making the Helmet

I decided to build this costume out of Foam. It was easier to work with, and took less time than a previous fiberglass build. I used hot glue to adhere the parts together, which was also nice and easy.

Next, I used a two part cast called "smooth on 65D" , and painted it on the outside of the helmet to give it a smooth, hardened look. It also gave it more strength. The downside was that painting it on left a lot of work for sanding, and then I had to apply 8-10 coats per part, just to get it to a nice thickness that i wanted. Needless to say, it was very time consuming, but worth it in the end.

Step 3: Body Parts ...

Once all the pieces are measured and cut, the body parts get assembled one, by one. For the chest and back parts, I reinforced the structure using thick wire that was easy to bend and form into the inside of the foam, and still keep its shape, and gave it more structure.

Step 4: Paint and Detail Beginnings...

Here I chose just flat black, very basic color scheme. I used some scrap wire for detail effects.

The arc reactor was a previous build that I did a while back... here is a link for that.

The chest parts were attached using velcro and straps. All leds, and electronic servos were powered by a few 9v batteries.

Step 5: Hands...

These were the most difficult to build, design, and make functional.

Step 6: Final Electronics and Details.

I did install servo's in the helmet, for the gun turret, and the jet pack. All are activated by a push button i modified on the chest piece for now.

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38 Discussions

how long did it take you to build that?

Could you possibly share the files you used for the foam build? Searching for Pepakura files to work with the thickness of foam is just not working out, seeing as they would be much different than the detail used in paper builds. Thanks!

how many foam sheet have you used

Hey, what did you use for the hinges on the helmet face plate?

where's the pdf to download the templates"

Could you please share the link for the pepakura files you used? I've looked every where on the web and can not find a valid link. The last one I tried, just installed a bunch of junk on my computer.


Great suit. I see a lot of people using the floor mats and wonder if I'm wasting my time trying to use craft foam. I should build some peps. I like the idea of using wire as support.

how many floor tiles did you use? what size were they?

Really nice design.

How did you create blue eyes and the blue chest piece? With some LEDs? How can you see through? thanks

Suppose you wish to give this a metal finish? Too easy; just use spray paint.

Suppose you would like to make it purely of metal somehow? Yes, you can use lost wax casting process, even make your own cheap propane refractory furnace to melt tin cans or even steel for about $300 maybe less.

Other methods include electroplating , vapor coating/deposition. If you are however unsatisfied with second best however, I can even explain how to produce super composites in zero gravity - super light and durable. A tech already used by our gov' courtesy of fine engineers like David Adair. If you're still not happy and wish to make a suit capable of zero point energy and antigravity with 900mph+ flight speed inside a protective ionosphere safe from bullets, well that's certainly possible even on a small budget.

What did you do to cover the seams, particularly in the helmet?

3 replies

I used smooth-cast 65D. It was ok, but this is mostly used for slush casting, not really used as a paint-on cast. It did leave a nice surface to finish, and filled in a lot of cracks and voids. But there was a lot of sanding, and lots of coats.

Oh man... just the answer I was looking for, which then prompts another question...

Have you used plasti-dip? If so, what difference did you notice? I'm considering both for when my suit is finished, and would love input. Though, I'm leaning towards smooth-cast right now.

This looks spectacular, especially when considering what it's made of. I never would have thought one could build something like this out of foam flooring tiles.

How do you see with the visor down? And do you have a link to the original files you used to make the foam template?