IronMan Fan Costume




My son is a huge fan of Iron Man and wanted to make a costume for Halloween. A box of insulation samples and a few hot glue sticks proved to be the perfect catalyst. Working freehand he simply cut up the sample with scissors and then hot glued them together.

The real Instructable here is working with the construction industry materials in a new and interesting way. The insulation is so easy to work with. It's also relatively cheap. A single roll should be enough to make an adult sized costume.

Step 1: The Materials

We used roofing insulation for the project. The material used is a closed-cell low-density polyethylene foam that has a premium quality, highly reflective aluminium foil on both sides. It's basically the insulation that usually goes below roofing. It's fantastic to work with. it can be formed easily and is clean to work

It cuts simply with scissors and joins perfectly with hot glue. With a bit of luck you could get off-cuts from a building site for little or no money.

Step 2: Your Imagination

My son just started cutting and gluing, making it up as he went along. The material was easy to curve, and the stuff he used was silver on one side and gold on the other, so it was easy to create contrast by reversing the colours.

Step 3: The Future

My son is currently working to add lights to the costume. Once again it will all held in place with hot glue. He's also 3D printing a centre chest piece.

Step 4: Conclusion.

Foam core insulation with hot glue is the quick and easy way to create freehand costumes for little or no money.

We hope you've enjoyed this Instructable.



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    6 Discussions


    3 years ago on Introduction

    Thanks guys for all the nice comments. I've passed these onto my son. Not bad for a 12 year old. ;)


    3 years ago on Introduction

    Really great final costume! Reminds me of some of the villains on the old Power Rangers. Is this foam insulation definitely safe to have in close contact with the body? Looks like a very cooperative medium.

    Wow, awesome job! I can't believe you just freehanded the whole thing! Make sure you enter it in the Halloween Contest this fall!


    3 years ago

    Nice. Great creative skills. he will definitely stay warm!


    3 years ago on Introduction

    Awesome! I love the unique approach, and original design!