Bazza's Iron-Man suit build

[AsignObservatory]

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.

[AsignObservatory]

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.

[AsignObservatory]

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.

[pearson]

Now something like that takes comittment! It's awesome!

[ving]

and the kids at work thought i was cool wearing a batman tshirt! wow baz, thats awesome!

[AsignObservatory]

Thanks guys!

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.

[AsignObservatory]

Right arm assembled, ready for hardening with resin.

[AsignObservatory]

Trial fit. Looking alright so far....

[tcdev]

Is there anything you cant do???

I hate people like you, Barry!

J/K of course, but I am extremely jealous! Perhaps one day I'll try to build stuff like observatories and Iron-Men suits - but more likely I'll chop my own arm off in the process.

[AsignObservatory]

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!

[achee]

That is AMAZING!

[Triz]

This is really awesome!

[achee]

Would that be how it is made for the movies?

[Tjfrnds]

Absolutely amazing!!

[AsignObservatory]

Would that be how it is made for the movies?

I think they would have far easier ways to do it....

- - - Updated - - -

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

[ameerat42]

Hey, the boss is watching you, Baz!

[chubb]

That is insane! cant wait for the rest of the build.

[AsignObservatory]

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.

[aussie girl]

I'm on to you Bazza!!! your going to put rockets in the feet and shoot up to the moon for some damn fine closeups, aren't ya Bazza!!!

just one question... with it being made of fibreglass resin, won't that make you itch like hell???

[AsignObservatory]

I'm on to you Bazza!!! your going to put rockets in the feet and shoot up to the moon for some damn fine closeups, aren't ya Bazza!!!

just one question... with it being made of fibreglass resin, won't that make you itch like hell???

You have stumbles upon my most secret plans!

Resin isn't itchy. It's the fibreglass mat that is itchy but only before it has been hardened with resin. The dangerous part then is if you leave hardened shards protruding so you have to sand it all down on the inside to get rid of them. After that, padding goes in anyway, providing a further barrier from the hardened inner shell.

Just having some fun with the phone camera.