Stealth Iron Man with Electronics and Servos

This outlines everything I did to create my first Iron Man suit with a mechanized helmet.  I have always loved the look and concept of Tony Stark's Stealth armor.  This was the first serious costume I ever made and it was a lot of learning through the entire process.  Start to finish took me about 8 months during my free time.  I'll caveat that all these techniques or methods are by no means my own and I have learned from many great people out there.  I am simply documenting the methods I used from all the wonderful resources out there on there net.

Here's my facebook page with more WIP pictures:
https://www.facebook.com/andrewscosplay

Here is also a grainy video of moving around in the armor.

And video of a horrible attempt of trying to dance in the suit

Photos courtesy of:
1 - David Lee, Popular Mechanics
2 - Caitlin Holland
3 - Aaron Berkovich Photography
4 - Aaron Berkovich Photography

Step 1: Form Paper Base

Materials I used for this stage:
-110lbs cardstock
-Graphtec / Silhouette SD Craft Cutter (formerly CraftROBO)
-Printer that can accommodate 110lbs cardstock
-Low temp hot glue gun + glue sticks
-Pepakura Designer
-Pepakura Viewer for Craftrobo

1) Find 3D model of the file you want to build.  Google does wonders.  The model I used for my Stealth Mk VI was made by robo3687.  These 3D models will serve as a rough geometric base of what you are trying to build
2) Download required software to open and print your paper model.  Software will show you how to glue pieces together to form the base shape of your model.
3) Cut 3D model pieces with Craftrobo
4) Use Pepakura viewer to assist you in glue required tabs together

Comments

[Bloodlessorc]

What paint did u use to make the suit?

[jackvbro]

very awesome dude but can u see through the eyes holes in the helmet or is it a light in the way?

[mizunohadouken]

I can see =P

[StocktonV]

The guys in the prop department where I work are going to love this, I know what we're doing for the next 8 months

[big pappy]

is the program that you used like solidworks??
love it btw cant wait to make my own!!!!

[Rob_283]

Is It hard to make one in another size? I mean, i'm quite small, will i be able to make one in my size?

[Leg007]

I was wondering, how much cardstock is needed and what size sheet?

[Laia_bee]

Hi! I´m really loving this tutorial. Since i actually speak spanish, would you be so kind explaining to me what steps 10 an 13 are? what do you mean by dust coat? Thank youuu ♥

[scoutmaster197]

great job - nice detail on the project

[Josh Jay]

CONGRATULATIONS! Great work man!

[mizunohadouken]

Thanks!

[poofrabbit]

Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!

[mizunohadouken]

Oh wow, thanks! I didn't even know until I saw your comment =P

[McNopants13]

Excellent suit my man, beautiful execution and i love the colour choice. i love using the Pepakura stuff its such a convenient way to make almost anything. hope to see more stuff from you in the future. all the best

[redsunmtm]

good job !
i was wondering: did Disney contact you for the right (just killing...)
may be for that reason you did it blue instead red ?
again good job, clean, and cool helmet !
(from a french user., well, ...reader)

[mizunohadouken]

Thank you! I just always liked the Stealth version

http://www.advancediron.org/images/iron-man-stealth-comiquette-sm.jpg

[PitStoP]

Very Cool. Wish I had the time to make something like this. Great job! Btw how long did it take to make?

[mizunohadouken]

Thanks! 8 months =P

[tha_jaker]

How did you control the face moving? Was there a button somewhere?

[mizunohadouken]

Yes, I think in one of the pictures of the microcontroller you can see the button attached to it.

[garcanno]

this is simply amazing. I'm glad i found this, i've been looking for a suitable method to make mechanical arm sleeves. I would just need 3d designs and what not. About how much does the whole suit weigh? I would like to know so i can make a rough estimate of how much a set of arms would weigh. Sorry in advance if my question is already answered in your instructable.

[mizunohadouken]

Fiberglass tends to be pretty light. I'm not sure the exact weight but it's not bad at all. It's more of a problem with stiffness and mobility.

[arsuman]

so pretty. and awesome. i so like it so much.

[SykoCaster]

What's the visibility like with that eye-light setup? I've been working on my own Iron Man armor and I've been experimenting with different options.

[mizunohadouken]

Hahah visibility kinda sucks, but that's okay. If you walk slowly you'll be fine. Kids are the danger zone because they are not really within your field of vision when your mask is down.... I've almost ran over a few kids =P.

[BigPupaSmurf]

If you ever decide to build another suit and for those who follow your instructions the guy over at xrobots came up with an idea to greatly improve visibility in his suit.

Great instructable, first Ive seen explaining how to trigger the eyes with the mask. I am new to electronics so this helps a lot. Thanks

[cool austin]

I love the suit. I have wanted to make one for awhile but couldn't fine good drawings or instructions. I might add some more features and put some weapons. How did they react at the comic con? That would be fun to go to. Good luck on the contest i voted.

[mizunohadouken]

You can google pepakura instructions for various projects, including iron man. People seemed to like the suit at comic con, though I didn't place in the Marvel Costume Contest. Oh well!

[lug big lug]

What papekura software(s) did you use?

[mizunohadouken]

I think if you google "pepakura designer" by tamasoft it should come up

[Darthscout]

that is wicked, can i have one?!

[cool austin]

I love the suit. I have wanted to make one for awhile but couldn't fine good drawings or instructions. I might add some more features and put some weapons. How did they react at the comic con? That would be fun to go to. Good luck on the contest i voted.

[monsterlego]

Fantastic!

[captain.hammer]

I was thinking about trying a similar project. Approximately how much in materials did you spend on this?

[mizunohadouken]

Sorry, I don't remember. I just kept buying supplies as I needed them. I experimented with different materials down the line as well so I didn't really keep track.

[invisiblelight386]

Best Iron Man Suit and most complete guide I have seen so far. Great work. I am planing to build one of these over the summer and i have been doing a lot of research. I'm pretty sure that i'm going with the Mark VI suit with the traditional colors. Love the idea of the paper cutter. About how much did this suit cost in supplies not including electronics? I am trying to see where my budget will fit in with this.

[invisiblelight386]

And if at all possible the quantity of material you used.

[mizunohadouken]

Hmmm I made a lot of mistakes and rework down the line since it was my first armor. I would probably say plan for $1000 to be safe, but it probably could be done for less. I don't remember the amount of material I used because I just bought stuff as I needed it.

[aman16]

can you send me the sketch up file link at [e-mail]
and your suit is awsome

[mizunohadouken]

Are you talking about the 3d model? You can google robo3687 pepakura to find it somewhere.