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This is my first attempt at building a Halloween Costume from scratch. Sorry I should have taken more construction photos but I got too involved with building. Overall it about 25 hours and about a thousand metal filing cuts on my hands. The outfit is not movie accurate and my son is 2 years old so he didn't care. The funny thing was that my wife pointed out about half way through construction is that he wants to SEE Ironman NOT be Ironman. So unfortunately this is the only time we wore the costume. He was supposed to be wearing black but I got so excited when he wanted to put it on that I didn't waste time waiting for him to change his mind. My 3 year old daughter actually wore the costume on Halloween because I think she felt sorry for me. Once again sorry about the jumping photos but I was not thinking ahead.
Step 1
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I started out purchasing red tin, a rivet gun, rivets, tin snips and paint. Then I proceeded to jump right in. I built the chest piece as a one piece unit from very basic measurements (ever try to measure a two year old). Once that was riveted together I built the shoulder pads and stomach wrap. Once completed I tried to put it on him and to my dismay ran away so my 3 year old daughter became the measurement model (she is such a trooper and daddy's girl). After some trial and error such as cutting the neck wider to no avail I realized the chest and back had to be a two piece unit.