Instructables
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 and my cosplay blog with more WIP pictures:
http://otakuandfit.com
https://www.facebook.com/andrewscosplay

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




And my friend and I running aroudn in Iron Man suits during Halloween 2012

Photos courtesy of:
1 - David Lee, Popular Mechanics
2 - Caitlin Holland
3 - Aaron Berkovich Photography
4 - Aaron Berkovich Photography
 
Remove these adsRemove these ads by Signing Up

Step 1: Form Paper Base

Picture of Form Paper Base
1 - cutter.JPG
1 - pep cut.JPG
1 - complete pep.jpg

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
bucktheman554 months ago

cool as bro I just want to know how you see

TheTeo4 months ago
How did you make the hands so detailed

what reed switch did you use?

pwert877 months ago
Did you do anything with the inside of the helmet or did you leave the fiberglass exposed?
zmankhawaja8 months ago
for the lights did u just change the LEDs color also if u want to make the original iron man colors can u do that?
lgchinadragon10 months ago
Great instructions!
Although, how do you open the file is the problem. Would you mind putting a zip with the pep files?
xarlock66710 months ago
That is the most bitchin thing I have ever seen!!! I want one! Love the helmet's servo too! How much is it?
tokidro11 months ago
what was total cost and time of this project
NanoRobotGeek11 months ago
Now... Where's that favorite button
seb203311 months ago
how much would you say it cost to make. I'm thinking of making a iron man suit or a batman suit.
maestro_dom11 months ago
Congratulation! Very nice suit! I was just wondering where did you place the button to open and close the facemask? Can`t find something trough the the various steps even in the videos...How does it work?
RickiDuff84211 months ago
Where could I get a copy of the paper base?
usMudack199811 months ago
Just a small question, did you take Robo's MarkVI suit and just make it black? I've been looking at trying to make the MarkVI suit and this just blew my mind. I only ask because I have the Pepakura files for the MarkVI and I really don't feel like downloading all of those files again.
Thanks!
-usMudack1998
Aoshido11 months ago
Words are beyond me man, really really nice job.
Looks amazing, as soon as i can i'll try to replicate it, and i'll swarm you with questions hahaha.
Once again my congratulations it looks awesome!
geeezer11 months ago
Respect! My mind is still boggling at the learning curves alone involved with a project like this... And the results are worth it ;)
Hey I plan on making this and I was just wondering what are the conditions while wearing it like is it hot heavy awkward to wear

rmckenzie1 year ago
Looks great! Are you able to sit down in it? I can't imagine going to a con, walking all over, standing in lines and not being able to sit for a minute.
What paint did u use to make the suit?
jackvbro1 year ago
very awesome dude but can u see through the eyes holes in the helmet or is it a light in the way?
mizunohadouken (author)  jackvbro1 year ago
I can see =P
StocktonV1 year ago
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 pappy1 year ago
is the program that you used like solidworks??
love it btw cant wait to make my own!!!!
Rob_2831 year ago
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?
Leg0071 year ago
I was wondering, how much cardstock is needed and what size sheet?
Laia_bee1 year ago
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 ♥
great job - nice detail on the project
Josh Jay1 year ago
CONGRATULATIONS! Great work man!
mizunohadouken (author)  Josh Jay1 year ago
Thanks!
poofrabbit1 year ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
mizunohadouken (author)  poofrabbit1 year ago
Oh wow, thanks! I didn't even know until I saw your comment =P
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
redsunmtm1 year ago
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 (author)  redsunmtm1 year ago
Thank you! I just always liked the Stealth version

http://www.advancediron.org/images/iron-man-stealth-comiquette-sm.jpg
PitStoP1 year ago
Very Cool. Wish I had the time to make something like this. Great job! Btw how long did it take to make?
mizunohadouken (author)  PitStoP1 year ago
Thanks! 8 months =P
tha_jaker1 year ago
How did you control the face moving? Was there a button somewhere?
mizunohadouken (author)  tha_jaker1 year ago
Yes, I think in one of the pictures of the microcontroller you can see the button attached to it.
garcanno1 year ago
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 (author)  garcanno1 year ago
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.
arsuman1 year ago
so pretty. and awesome. i so like it so much.
SykoCaster1 year ago
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 (author)  SykoCaster1 year ago
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.
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
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 (author)  cool austin1 year ago
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!
What papekura software(s) did you use?
mizunohadouken (author)  lug big lug1 year ago
I think if you google "pepakura designer" by tamasoft it should come up
Darthscout1 year ago
that is wicked, can i have one?!
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.
Fantastic!
I was thinking about trying a similar project. Approximately how much in materials did you spend on this?
mizunohadouken (author)  captain.hammer1 year ago
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.
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.
And if at all possible the quantity of material you used.
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.
aman161 year ago
can you send me the sketch up file link at amanmalhotraa@yahoo.com
and your suit is awsome
mizunohadouken (author)  aman161 year ago
Are you talking about the 3d model? You can google robo3687 pepakura to find it somewhere.
ksykes1 year ago
Great job! I love how you have the helmet opening and the lights going on and off.
You could probably make money off of this. Thanks for putting it on the internet for free instead.
Honus1 year ago
Awesome suit! It looks really sharp and the helmet action is nice too.

How do you like the Silhouette cutter?
mizunohadouken (author)  Honus1 year ago
Thanks bud! I love the cutter.... saves me a lot of time. I think the one I have isn't for sale anymore, but the next iteration is the "cameo" i think
Acerix1 year ago
Can you tell me how to apply the Bondo equally? Im having trouble with it.
mizunohadouken (author)  Acerix1 year ago
I actually cut a plastic body filler spreaders to different lengths and used different ones depending on the shape of the surface. I basically used smaller spreaders for tight and curvy spaces. You can google some auto body videos on how to apply body filler for some tips.
Amazing build, and that helmet action is spot on!
mizunohadouken (author)  mikeasaurus1 year ago
Thank you sir! Took a lot of experimenting to get it working. Not quite movie accurate, but I think it's okay for me.
wow man... i cant beleive this was paper! for my next halloween costume, i want to make something that is either armour or a crazy mask. you might have changed my mind to this though!
That is very, very cool! Are you standing on the set of Iron Man in that one picture???
Hey thanks! Yes, and no. That was at San Diego Comic Con where they brought the Hall of Amor set of Iron Man 3 to the Marvel booth. Thanks for the compliment!
That is so very cool too! I just can't believe this started with paper, and I love the color choice!