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  1. Member Since
    Oct 2008
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    42
    Oct 30, 2008, 3:06 PM - Forging a new Iron Man #1

    I am new here to the dented helmet but am not new to prop building in general. I have decided to start an Iron Man project and wanted to share progress with all of you out there. I have seen the Iron Man costume by TMP and I must say how impressive that truly is. I would buy a costume but I want one that is going to truly mimic the movie costume.
    I have decided to create an Iron Man costume that is the precise size of the one in the costume, one that is as close as possible and still able to be worn and have movement. It should be the same or similar dimensions to the one in the movie. I basically want to start this thread to just show the progress overall.
    I have just begun the project and don't have the luxury of working on it every day. I intend to post updates with pictures to get any opinions you all may have. This will be a labor of love for me as I have always liked Iron Man. I hope you all will follow along with my progress. I am a firm believer that by sharing all of our work with eachother, we all get better.

    The project is made out of .5 inch blue foam. I have never used this medium before so there is of course a learning curve. Enjoy.

    It all started with a design on the foam and started to carve it.
    As it was a few days ago.
  2. Oct 30, 2008, 3:09 PM - Re: Forging a new Iron Man #2

    that's pretty sick bro. can't wait to see the finished product
  3. Oct 30, 2008, 3:41 PM - Re: Forging a new Iron Man #3

    most excellent work there. Looking forward to seeing it through it's stages
  4. Bubba Fett's Avatar
    Member Since
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    Oct 30, 2008, 4:01 PM - Re: Forging a new Iron Man #4

    Looking good. I used to always use surfboard foam, it has a great consistency and is easy to work with.

    It did freak out the guy though when I went to Santa Cruz and bought a blank from a surf shop then proceeded to cut it in half to fit it in the car. The guy came out screaming "you can't build a board out that now man!!!"
  5. Madmartigan's Avatar
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    Jun 2008
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    Oct 30, 2008, 4:34 PM - Re: Forging a new Iron Man #5

    Bubba Fett said: View Post
    Looking good. I used to always use surfboard foam, it has a great consistency and is easy to work with.

    It did freak out the guy though when I went to Santa Cruz and bought a blank from a surf shop then proceeded to cut it in half to fit it in the car. The guy came out screaming "you can't build a board out that now man!!!"
    He probably had nightmares about the Surfboard Slasher for weeks!!
  6. askywalker98's Avatar
    Member Since
    Jan 2004
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    Oct 30, 2008, 6:56 PM - Re: Forging a new Iron Man #6

    That's awesome craftsmanship, but... doesn't it seem a bit thin? I'm looking at my hand the way your holding it up, and it seems like it's not wide enough from ear to ear. Maybe it's your camera?
  7. Predatormv's Avatar
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    Oct 30, 2008, 9:52 PM - Re: Forging a new Iron Man #7

    Looking good bud, I can't wait to see how it comes out.
  8. Rich D.'s Avatar
    Member Since
    Nov 2005
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    729
    Oct 30, 2008, 10:13 PM - Re: Forging a new Iron Man #8

    Nice work. What tools do you use to remove foam during the carving stage? blades? dremel? it all looks hand-carved.
  9. Member Since
    Oct 2008
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    Oct 30, 2008, 11:13 PM - Re: Forging a new Iron Man #9

    askywalker98 said: View Post
    That's awesome craftsmanship, but... doesn't it seem a bit thin? I'm looking at my hand the way your holding it up, and it seems like it's not wide enough from ear to ear. Maybe it's your camera?
    The camera angle is a bit off, but I believe it is close to the right size. At least the schematics started off that way. There is absolutely no way that the helmet will fit as a one piece like fett or a stormtrooper. Instead it will have to assemble/disassemble similar to the movie. It may not fit someone with a large head either. If you see the movie stills there is no bobble head. In fact it is streamlined much to the exact size as a human head. Thus no room.

    I will take some measurements tommorrow.
  10. Member Since
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    Oct 30, 2008, 11:34 PM - Re: Forging a new Iron Man #10

    Count Dookie said: View Post
    Nice work. What tools do you use to remove foam during the carving stage? blades? dremel? it all looks hand-carved.
    This stuff doesn't work as well as other foams. I am using a dremel and a sander. But I don't think I can glass over it. Instead I intend to use bondo and then sand that down to proper size.
  11. I helped at SDCC '08 987654321a's Avatar
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    Oct 31, 2008, 12:10 AM - Re: Forging a new Iron Man #11

    It is shaping up well. Looks good man. Keep it up.
  12. t_bone9600's Avatar
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    Oct 31, 2008, 8:07 AM - Re: Forging a new Iron Man #12

    Test the bondo on a scrap piece of foam first. Sometimes bondo has a tendancy to dissolve styrofoam. Especially if it is soft to start with. Might not hurt to test some glass too. It may not be as corrosive to the foam.
  13. Member Since
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    Oct 31, 2008, 9:12 AM - Re: Forging a new Iron Man #13

    I made a dragon scuplture out of pink foam, definitely beware of resin dissolving it. Nice work, and by the way you will be finding bits of blue foam around the house for years. Its a great medium, but I wouldn't rely on it to hold too many fine details.
  14. Member Since
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    Oct 31, 2008, 9:19 AM - Re: Forging a new Iron Man #14

    Yeah, if you sand it, it'll look nice, but oh god what a mess. It gets static charged sticks to everything... terrible :P Your sculpt looks awesome though, you've got some skills there.
  15. Member Since
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    Oct 31, 2008, 10:35 AM - Re: Forging a new Iron Man #15

    t_bone9600 said: View Post
    Test the bondo on a scrap piece of foam first. Sometimes bondo has a tendancy to dissolve styrofoam. Especially if it is soft to start with. Might not hurt to test some glass too. It may not be as corrosive to the foam.

    Thanks for the heads up. I should try the bondo on some other pieces. Everyone is right about the foam not holding the finest of details. it is also next to impossible to get it completely smooth, thus the reason for thinking bondo next.

    I have been doing the project outside as this blue stuff goes everywhere. I should post another update today although I am at work.

    Has anyone ever used this as a medium and tried to continue the project in another manner, ie. glass, plaster bandages or plastic?
  16. Member Since
    Oct 2008
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    Oct 31, 2008, 11:13 AM - Re: Forging a new Iron Man #16

    If you can find a resin that will not dissolve the foam I would coat it with that first. The bondo will try to adhere to the foam and when you sand areas where the bondo is thin it may have a tendency to flake up and take chunks of foam with it. your best bet actually is to use some kind of water based polymer putty that air dries, coat it and detail with that. Then use that as a plug to make a rubber or fiberglass mold. Use the mold to then create your actual armor pieces. The foam should be a prototype, it is not strong enough to resist damage from even light use. I used foam as the core in the head of my godzilla costume but that was because it was a solid brick of foam and the features were very blunt. It was covered in felt and that shell allowed it to stay pockmark and dent free. A mask is going to be too thin. In my opinion at least.
  17. Member Since
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    Oct 31, 2008, 12:40 PM - Re: Forging a new Iron Man #17

    Racin Vhett said: View Post
    If you can find a resin that will not dissolve the foam I would coat it with that first. The bondo will try to adhere to the foam and when you sand areas where the bondo is thin it may have a tendency to flake up and take chunks of foam with it. your best bet actually is to use some kind of water based polymer putty that air dries, coat it and detail with that. Then use that as a plug to make a rubber or fiberglass mold. Use the mold to then create your actual armor pieces. The foam should be a prototype, it is not strong enough to resist damage from even light use. I used foam as the core in the head of my godzilla costume but that was because it was a solid brick of foam and the features were very blunt. It was covered in felt and that shell allowed it to stay pockmark and dent free. A mask is going to be too thin. In my opinion at least.
    This foam is nothing more than the base of the master so to speak. The helmet itself will contain no foam at all. Instead, it will be entirely fiberglass. I am looking for a material to coat the foam which will A) not dissolve the foam and B) will accept a fiberglass shell. I think I will just need to try it out on a scrap piece. Updates to follow.
  18. Admin Staff webchief's Avatar
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    Oct 31, 2008, 2:42 PM - Re: Forging a new Iron Man #18

    Looking mighty impressive!
  19. Member Since
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    Oct 31, 2008, 3:34 PM - Re: Forging a new Iron Man #19

    Here are some pics as of yesterday afternoon. The dimensions are as follows: Length - aprox 10 inches
    Width - aprox 7 inches
    Height- aprox 11 inches
    Circumference - aprox 30 inches

    The ear details are not finished and the back of the head is a bit crooked and has also not been finished. I just took these pics for measurement although the pictures aren't that great.
  20. Loanstar's Avatar
    Member Since
    Mar 2002
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    Nov 3, 2008, 5:58 AM - Re: Forging a new Iron Man #20

    Just make sure that the helmet is big enough.
    I have seen 3 or 4 helmets the last months that all where a bid to small.

    If you like, I can send you some pictures of what Im talking about.

    Mike
  21. Member Since
    Oct 2008
    Posts
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    Nov 15, 2008, 9:56 AM - Re: Forging a new Iron Man #21

    Loanstar said: View Post
    Just make sure that the helmet is big enough.
    I have seen 3 or 4 helmets the last months that all where a bid to small.

    If you like, I can send you some pictures of what Im talking about.

    Mike

    Sure pics are welcome thanks.
  22. Member Since
    Jan 2010
    Posts
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    Jan 24, 2010, 9:39 AM - Re: Forging a new Iron Man #22

    What ever happend with this??

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