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Thread started 27 Feb 2013 (Wednesday) 05:34
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Bazza's Iron-Man suit build

 
A.S.I.G.N. ­ Observatory
...For the future of mankind
A.S.I.G.N. Observatory's Avatar
Joined Aug 2008
Canberra, Australia
Post has been edited over 1 year ago by A.S.I.G.N. Observatory.
Feb 27, 2013 05:34 |  #1

EDIT: I've moved onto a FULL STEEL BUILD since this original Iron Man was started. Go to the last page to see where it's up to.


IMAGE: http://i.imgur.com/NiPFP1d.jpg

IMAGE: http://i.imgur.com/TUotu8w.jpg

IMAGE: http://i.imgur.com/WW09LTE.jpg


On with the story from the beginning........

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

Photographing this project has been good practice in a sort of product photography theme.

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

IMAGE: http://i.imgur.com/4xsJt.jpg
IMAGE: http://i.imgur.com/gn5AB.gif

And a short video of the faceplate moving:

http://www.youtube.com​/watch?v=Wb9q0Rv7_OM=y​outu.be (external link)

The arc reactor

IMAGE: http://i.imgur.com/fio77.jpg

IMAGE: http://i.imgur.com/r8sXb.jpg

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.

IMAGE: http://i.imgur.com/zRb9HZL.jpg

The entire build is on my ASIGN website, as a rainy day project. >>> http://www.asignobserv​atoryii.com ...os/album?albumid=13​968067 (external link)

Builds By Baz website http://www.buildsbybaz​.com (external link)

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A.S.I.G.N. ­ Observatory
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Feb 27, 2013 05:34 |  #2

Coming together...

IMAGE: http://i.imgur.com/RiAa3uo.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

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A.S.I.G.N. ­ Observatory
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Feb 27, 2013 05:35 |  #3

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.

IMAGE: http://i.imgur.com/3J8KcKq.jpg

2. Rough filler application continues around the left side.
IMAGE: http://i.imgur.com/nCT7w3s.jpg

3. Now getting a bit of an idea of symmetry for adjustment.
IMAGE: http://i.imgur.com/zLrqXQn.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

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DBNissan
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NorCal's Delta Valley
Feb 27, 2013 05:40 |  #4

Very creative! Good job!


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DeaconG
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Feb 27, 2013 10:08 |  #5

Impressive!


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IShootThings
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North Cali
Feb 27, 2013 12:22 |  #6

That is awesome!


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A.S.I.G.N. ­ Observatory
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Canberra, Australia
Mar 02, 2013 01:44 |  #7

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.

IMAGE: http://i.imgur.com/qrKJXWO.jpg

IMAGE: http://i.imgur.com/ux8JwVr.jpg

The sanding continues.

IMAGE: http://i.imgur.com/jZwzu32.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

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Scatterbrained
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Mar 02, 2013 01:51 |  #8

Subscribed! :)


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YamahaRob
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Mar 02, 2013 02:09 |  #9

Gonna try to make it fly also?:lol:


Ya got alot more patience than I do.


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A.S.I.G.N. ­ Observatory
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Mar 02, 2013 02:15 |  #10

YamahaRob wrote in post #15667529external link
Gonna try to make it fly also?:lol:


Ya got alot more patience than I do.

You'd be surprised how many people ask me that.... :lol:


Builds By Baz website http://www.buildsbybaz​.com (external link)

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A.S.I.G.N. ­ Observatory
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Mar 02, 2013 04:25 |  #11

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.

IMAGE: http://i.imgur.com/zPq4ra9.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

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A.S.I.G.N. ­ Observatory
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Canberra, Australia
Mar 03, 2013 07:15 |  #12

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.

IMAGE: http://i.imgur.com/J9CtCUt.jpg
IMAGE: http://i.imgur.com/JvF6NTM.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

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A.S.I.G.N. ­ Observatory
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Mar 13, 2013 07:37 |  #13

Right arm assembled, ready for hardening with resin.

IMAGE: http://i.imgur.com/723nTE5.jpg

Builds By Baz website http://www.buildsbybaz​.com (external link)

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katodog
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Mar 13, 2013 07:43 |  #14

Subscribing...because that is some cool, cool work!!!


The only stupid question is the one that goes unasked - Photographers shoot to thrill, not to kill
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S.n.a.f.u.
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Mar 13, 2013 08:04 |  #15

creative fusion of two hobbies! i look forward to more updates!


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Bazza's Iron-Man suit build
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