Finishing the rigid Iron Man suit

This page is about finishing the rigid suit, check out the main project index for the rest.

This part of the project is in progress, I will post updates as I go. Each piece of the suit is being cast from the moulds, either in Polyurethane plastic, or fiberglass.

Here are some YouTube videos, or scroll down for the words and pictures:

Here is the current state of the rigid pieces on 10th December 2012. Note that the boots are propped at the front of the legs in the shot of the whole suit. Each piece is also pictured below:

Each piece of the suit has had a mould made from the foam suit, then been cast in plastic, cleaned up, filled and sanded and primed. First the helmet was cast and sanded. The white one on the left in the first picture is the cleaned up version, the other is a raw cast:

Then car body filler was used, more sanding, filling, sanding and primer again:

My original ab plate was bolt flat, so once I'd cast the plastic version I heated it up and stretched the curve into it, followed by sanding, filling etc:

Here's the back of the torso being cast etc:

Here's the back and front together, I've left some overlap so there's something to latch them together with:

Shoulder bells, which were pretty bad casts:

After a lot of clean up:

Biceps:

Forearms:

Leg moulds and my first cast, which have been cleaned up slightly. Check out the leg moulding article.

Raw casts of the boots and thighs in fiberglass, check out the video at the top to see how they were made:

I've made vacuum formed pieces to replace the side panels of the thighs, which will also act to hold the two halves together and latch them onto the exoskeleton strapping system:

Here are the thighs after multiple passes of sanding and filling, still some more to do:

Completed boots, check out the Exoskeleton Strapping System page for more on these:

Pictures and details of the hands have their own project page: