XRobots - Iron Man & War Machine pepakura costume suit foam build, sealing and painting process

This video shows how I made a my Iron Man suit pieces, and the principles behind painting and sealing foam. The rest of the Iron Man project can be found at: http://www.xrobots.co.uk/IM6

You can join my page on facebook here: http://www.facebook.com/XRobots.co.uk

The title music is also written and performed by me, copyright XRobots.co.uk

Category:

Howto & Style

Tags:

• Iron
• Man
• foam
• suit
• costume
• build
• sealed
• sealing
• and
• painting
• process
• includes
• War
• Machine
• pieces
• cosplay
• costuming
• larp
• sculpting
• moulding
• casting
• convention
• anime
• educational
• plaster
• mould
• sculpt
• cast
• making
• pepakura
• hot
• glue

[Shintenzu]

I was wondering two things. If your glued seams have gaps and are not as flushed as you would want them to be, what kind of filler could I use to close these gaps and smooth rough edges on foam armor? Also what could I used to add smoth embossed designs onto a foam armour piece (The suit Im working on is more medieval so alot of decorative embossments). Thank you very much, your video is amazing, I'm already subscribed and anxious for more.

[jamesbruton]

@Shintenzu I used car body filler, but this only works because I covered the foam with PVA, otherwise it won't stick. Apparently you can do embossing with a soldering iron or something else hot that would melt the foam.

[Comguard1]

Very interesting video! I always wanted to build an armor with Prepakura, but the resin and fibreglassing really scared me off.

Could you tell me which thickness you used for the EVA foam?

[jamesbruton]

@Comguard1 it's 10mm

[Comguard1]

@jamesbruton

Thanks for the quick answer. I just have to answer one more thing: how stable is the costume? Obviously you wanted to use it as a wearable costume (otherwise why bother painting?), but then you used it for creating a molded costume. Unsatisfied with the results, or just "aim higher"? As a Halloween costume there is the problem with sitting on chairs, wonder if the foam flexes back into position.

[jamesbruton]

@Comguard1 Yes, I just fancied a rigid suit too - and that one will be better because I can send, fill and finish the plastic it's cast from. Once the foam is painted with PVA you need to treat it as a rigid suit really, if you bend it too far the paint will crack.

[SuperDH27]

some people worship god god worships you

[DEATH111183]

one method that you might find works a bit better than pva to give ya that glossy metalic look i recommend would be ether liquid tape "the stuff used for splicing wires" being it's a very flexable rubber. and or a latex base clearcoat. these will allow the foam to still flex easy enough and not crack when flexed. i know i don't have a vid on my work.....trying to make a unique design soo, till then all of youtube will have to wait

[DJWandrix]

Great job! Please, what do you use to harden boards eva?

[villehermannivalo666]

@villehermannivalo666 and also where did you get the foam from as im struggling to find some in this country (uk)

[villehermannivalo666]

hey i was wondering when you cover the suit in pva glue does it crack at all with movement as im going to make this for halloween (had a bad time with resin)

[RoadCopEagle]

I am making the Brief case armour for my ironman costume so is there any tips you could give me please.

[mrcolinjohn1980]

Love it mate

[batmany2k]

wow you are so amazing do you do this for fun or this is part of your work wow

thanks i may have to try this .........thank you.....batcuffs