For this build I started with the helmets. The first one I made was too round and too small, but it worked in a pinch for a Tony Stark cosplay as a carry-around prop. This started, as before, from a pep file adapted for foam.
The final product:
After that was ready, it was time to throw on the ear pucks. These I made with foam again, rounded down with my table router, and a shaped piece of 1/16" styrene (remember those For Sale signs?) on top for detail.
The Mark VII was easier:
Lots more basic shapes, meaning easier making but I'll have to wait to paint until the back section is ready to attach. Needs the curve to be just right!
The helmets, if you're wondering, were both being painted while I worked on the chest pieces. Since I'm making two suits at once, and one is for a customer, I'm trying to multitask as much as possible to speed up the process. Now, there were quite a few seams I wanted to cover, so I tried out a new technique: resin. Of course, I thought that meant polyurethane, and now know that means Epsilon, so watch and learn from my sad mistakes.
That took forever and barely worked, so I decided to test paints on them while I gathered funds to get Mod Podge to smooth that all out. Before that, though, I took a break from foaming and decided to have a go at the Arc Reactor and the lighting for the eyes!
For the eyes, it's the same plastic sanded up, backed with black craft foam that has tin foil attached. This spreads the light a bit better, and keeps it from blinding the wearer.
Back to the painting....
Unfortunately I haven't done any work on either of them in several months, as the person who commissioned me originally has dropped out of contact. They wanted the helmet by the release of IM3, but have only paid the deposit with nothing since. If they haven't made any more payments by the promised completion date, you may see at least one of these helmets up for sale.
We shall see though! I will definitely post more updates on this when I have a chance to make more of mine. Onward!