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Bazza's Iron-Man suit build

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  • Bazza's Iron-Man suit build

    Hey guys and girls, I thought a few of you might appreciate this for fun.

    I've been building an Iron-Man suit to fit me, using a technique called Pepakura. It starts off with a paper chassis, scaled to fit and printed off on A4 card stock. It is then cut out in all it's pieces, folded, glued together then painted inside and out with fibreglass resin. Then you mix resin with car-body filler to make a slush-cast, pour it on the inside and slush it all around. Then you coat the inside with fibreglass mat for strength. Then you paste car-body filler on the outside and start sanding, shaping and detailing. Finally, undercoats, painting and kit the inside out with padding, lights, and in my case, some animatronics to make parts move.

    This is where I'm at so far, as of mid-Feb 2013.....

    The helmet




    Video below of the faceplate moving with motors:

    http://www.youtube.com/watch?v=Wb9q0Rv7_OM=youtu.be

    The arc reactor





    The suit

    The suit is now ready for the bench. Now that the waist is hardened, it's time to fit it inside the torso to begin hardening the torso in shape. While the fibreglass inside was curing, I modified the arc-reactor and fit it inside it's housing in the torso. I found a beautiful big glass lens out of an old overhead projector and it fits EXACTLY over the top of the arc-reactor, sealing it into the suit.



    The entire build is on my ASIGN website, as a rainy day project.
    Australian Wildlife Photographer

    Barry Armstead Photography
    ASIGN Observatory II

  • #2
    Looks incredible but sounds very complicated and time consuming. Where do you find the time for all your projects?

    Comment


    • #3
      Originally posted by P Plates View Post
      Looks incredible but sounds very complicated and time consuming. Where do you find the time for all your projects?
      Between ten PM and midnight.....
      Australian Wildlife Photographer

      Barry Armstead Photography
      ASIGN Observatory II

      Comment


      • #4
        Wow!!! It looks so technical, i wouldn't like to meet you on a dark night with that on, you must be very creative

        Comment


        • #5
          Originally posted by Jcas View Post
          Wow!!! It looks so technical, i wouldn't like to meet you on a dark night with that on, you must be very creative
          Just standing on the shoulders of giants mate!
          Australian Wildlife Photographer

          Barry Armstead Photography
          ASIGN Observatory II

          Comment


          • #6
            That is possibly the coolest thing I've ever seen

            Comment


            • #7
              can't wait to see the finished product...love the dedication
              Nathanial
              My Flickr
              Canon 5D3 __ 17-40mm L

              Comment


              • #8
                Originally posted by flap View Post
                can't wait to see the finished product...love the dedication
                Keep your eye on the website gallery mate, I can't keep up with all the forums!
                Australian Wildlife Photographer

                Barry Armstead Photography
                ASIGN Observatory II

                Comment


                • #9
                  Re: Bazza's Iron-Man suit build

                  I have to laugh Barry. First Asign II and now this, is this your idea of contraception ? You realise your little too young for dressups.

                  Sorry, couldn't help it. You are indeed very creative.

                  Sent from my GT-I9100 using Tapatalk 2
                  Anna
                  https://www.flickr.com/photos/ladymilli/
                  My stuff - 7D |100mm macro|Tamron 17-50mm|50mm 1.8|Sigma 50mm 1.4| stuff for macro

                  Comment


                  • #10
                    Originally posted by millicat View Post
                    I have to laugh Barry. First Asign II and now this, is this your idea of contraception ?
                    Well obviously it's not working, I just had a son......
                    Australian Wildlife Photographer

                    Barry Armstead Photography
                    ASIGN Observatory II

                    Comment


                    • #11
                      Yes the one you had last year ...I mean to prevent more !!! lol
                      Anna
                      https://www.flickr.com/photos/ladymilli/
                      My stuff - 7D |100mm macro|Tamron 17-50mm|50mm 1.8|Sigma 50mm 1.4| stuff for macro

                      Comment


                      • #12
                        Originally posted by millicat View Post
                        Yes the one you had last year ...I mean to prevent more !!! lol
                        2 more in the wind...
                        Australian Wildlife Photographer

                        Barry Armstead Photography
                        ASIGN Observatory II

                        Comment


                        • #13
                          wow this is so cool sounds like a lot involved though but pretty neat
                          All Experts at anything were once beginners





                          MWAH Sandy

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                          • #14
                            that is pretty cool stuff, must require a bit of patience
                            Cheers
                            Darren
                            website

                            Comment


                            • #15
                              Coming together...

                              Australian Wildlife Photographer

                              Barry Armstead Photography
                              ASIGN Observatory II

                              Comment


                              • #16
                                Wow, you would have to be the coolest dad ever in that suit.

                                Comment


                                • #17
                                  You are one fascinating character Bazza, love seeing what you get up to.
                                  http://www.flickr.com/photos/[email protected]/
                                  Haven't been there, not done that.
                                  Jo

                                  Comment


                                  • #18
                                    Originally posted by Phoenix View Post
                                    You are one fascinating character Bazza, love seeing what you get up to.
                                    I love surrounding myself in the strange, weird and different..... that's where all the interesting people hang out!

                                    Baz.
                                    Australian Wildlife Photographer

                                    Barry Armstead Photography
                                    ASIGN Observatory II

                                    Comment


                                    • #19
                                      1. I've found that a very light spray of colour (and I mean light), can help in the sanding process to clearly identify low-spots. The downside is that if you spray too heavy, the paint can very quickly clog your sandpaper.


                                      2. Rough filler application continues around the left side.


                                      3. Now getting a bit of an idea of symmetry for adjustment.
                                      Australian Wildlife Photographer

                                      Barry Armstead Photography
                                      ASIGN Observatory II

                                      Comment


                                      • #20
                                        Looking good Barry. btw I like how you have an outline of your tools that are hanging on our shed wall. That way if you are lazy and haven't put your 'toys' away, the wife can come in and match the tool with the outline lol. Very cool.
                                        Anna
                                        https://www.flickr.com/photos/ladymilli/
                                        My stuff - 7D |100mm macro|Tamron 17-50mm|50mm 1.8|Sigma 50mm 1.4| stuff for macro

                                        Comment


                                        • #21
                                          Originally posted by millicat View Post
                                          Looking good Barry. btw I like how you have an outline of your tools that are hanging on our shed wall. That way if you are lazy and haven't put your 'toys' away, the wife can come in and match the tool with the outline lol. Very cool.
                                          Thanks Anna. It's called a shadow-board and I have to finish it. Every tool has a place and it makes it soooo much easier to find things and put things back where they belong!
                                          Australian Wildlife Photographer

                                          Barry Armstead Photography
                                          ASIGN Observatory II

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                                          • #22
                                            I've been trying several iterations of arc reactor because the first one is not bright enough. I think I'm happy with this third attempt.





                                            The sanding continues.

                                            Australian Wildlife Photographer

                                            Barry Armstead Photography
                                            ASIGN Observatory II

                                            Comment


                                            • #23
                                              Night-time project - Iron Man's arms. preparing to cut all the parts out of 23 sheets of 200gsm card-stock per arm, before folding, gluing and hardening.

                                              Australian Wildlife Photographer

                                              Barry Armstead Photography
                                              ASIGN Observatory II

                                              Comment


                                              • #24
                                                Here's over 8 hours work last night and today. Upper arm/bicep and shoulder-bells for right arm constructed from card-stock ready for resin hardening. Fits my arm nicely.


                                                Australian Wildlife Photographer

                                                Barry Armstead Photography
                                                ASIGN Observatory II

                                                Comment


                                                • #25
                                                  Had a friend come over yesterday. I bogged up the torso while he applied resin to all the arm components. Today I filled each piece with a 4:1 slush-mix of car-body-filler and fibreglass resin. Rock solid on the inside now, ready for fibreglass matt on the inside then filler on the outside for sanding and detailing.


                                                  Checking for proportions, this thing is looking MEEEAANNN! Can't wait to put it on!
                                                  Australian Wildlife Photographer

                                                  Barry Armstead Photography
                                                  ASIGN Observatory II

                                                  Comment


                                                  • #26
                                                    Wow I so admire your dedication to the project, also your know how, yes it does look rather mean, i wouldn't like to bang into you on a dark night with it on.

                                                    Comment


                                                    • #27
                                                      Originally posted by Jcas View Post
                                                      Wow I so admire your dedication to the project, also your know how, yes it does look rather mean, i wouldn't like to bang into you on a dark night with it on.
                                                      Neither would the dark knight.....
                                                      Australian Wildlife Photographer

                                                      Barry Armstead Photography
                                                      ASIGN Observatory II

                                                      Comment


                                                      • #28
                                                        You are no ordinary geek Barry, truly you are a star amongst geeks.
                                                        http://www.flickr.com/photos/[email protected]/
                                                        Haven't been there, not done that.
                                                        Jo

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                                                        • #29
                                                          Seems someone was spying on my top-secret project with an iPhone.....

                                                          Australian Wildlife Photographer

                                                          Barry Armstead Photography
                                                          ASIGN Observatory II

                                                          Comment


                                                          • #30
                                                            Fitting finished pieces together is proving quite difficult. The pepakura files show you how to make the pieces, but not how to fit them together.

                                                            I've now filled each arm-piece with slush-cast, but not yet reinforced them with fibreglass mat. I wanted to check for fit first.

                                                            I put the shoulder bell on, upper arm, forearm and wrist with the elbow pivot plate in between. Bent my elbow and promptly broke the pivot plate. I think I might make one (temporary template) out of cardboard, fit it and get it working, then make one out of aluminium plate.

                                                            It fits well though. Nice and snug with just a little room for padding inside.

                                                            Australian Wildlife Photographer

                                                            Barry Armstead Photography
                                                            ASIGN Observatory II

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