Bazza's Iron-Man suit build

[AsignObservatory]

Hey guys and girls, I thought a few of you might appreciate this for fun.

I've been building an Iron-Man suit to fit me, using a technique called Pepakura. It starts off with a paper chassis, scaled to fit and printed off on A4 card stock. It is then cut out in all it's pieces, folded, glued together then painted inside and out with fibreglass resin. Then you mix resin with car-body filler to make a slush-cast, pour it on the inside and slush it all around. Then you coat the inside with fibreglass mat for strength. Then you paste car-body filler on the outside and start sanding, shaping and detailing. Finally, undercoats, painting and kit the inside out with padding, lights, and in my case, some animatronics to make parts move.

This is where I'm at so far, as of mid-Feb 2013.....

The helmet

http://i.imgur.com/4xsJt.jpg
http://i.imgur.com/gn5AB.gif

Video below of the faceplate moving with motors:

http://www.youtube.com/watch?v=Wb9q0Rv7_OM=youtu.be

The arc reactor

http://i.imgur.com/fio77.jpg

http://i.imgur.com/r8sXb.jpg

The suit

The suit is now ready for the bench. Now that the waist is hardened, it's time to fit it inside the torso to begin hardening the torso in shape. While the fibreglass inside was curing, I modified the arc-reactor and fit it inside it's housing in the torso. I found a beautiful big glass lens out of an old overhead projector and it fits EXACTLY over the top of the arc-reactor, sealing it into the suit.

http://i.imgur.com/zRb9HZL.jpg

The entire build is on my ASIGN website (http://www.asignobservatoryii.com/apps/photos/album?albumid=13968067), as a rainy day project.

[hakka]

Awesome. how many hours has it taken so far?

[Danielle10]

Love it!!

[ricktas]

The kids will think you are awesome!

[AsignObservatory]

Awesome. how many hours has it taken so far?

I've lost count....

Can't wait to attend McHappy day in the drive-through in it! Kids will go beserk! :D

[andrewvid]

I have the same heater :D That looks so awesome!! Can't wait to see the finished product!

[Rattus79]

That looks Brilliant!
Don't limit yourself to just McHappy day, Contact your local Ronald Mc Donald house. They're always full of kids that need a good smile!
Some of the stories the parent's tell will melt your Arc Reactor and bring a tear to your electronic eyes!

[AsignObservatory]

That looks Brilliant!
Don't limit yourself to just McHappy day, Contact your local Ronald Mc Donald house. They're always full of kids that need a good smile!
Some of the stories the parent's tell will melt your Arc Reactor and bring a tear to your electronic eyes!

I'm sure other opportunities will present themselves....

Cheers dudes.

[ameerat42]

The kids will think you are awesome!

And as you ride off on your astro-steed, some old timer will ask, "Who was that masked man?"

[wedgtail]

Fantastic work very informative

[mechawombat]

Is there anything you cant do???

This looks AMAZING and brings a smile to this kids face too!

[calmaxgan]

Wow - there's a lot of work in that!!

[kiwi]

Look up ironmate

Aussie version and Cosplay feature


Sent from my iPad using Tapatalk

[AsignObservatory]

Thanks guys. It's a great budget project to keep me amused when I can't afford my bigger ones.

Baz.

[Steve Axford]

Always fascinating to hear what you are doing. Quite different from the norm. Hope you can afford the bigger ones soon.

[glennb]

Thats awsome, would love one as a stormtrooper. :cool:

[AsignObservatory]

Thats awsome, would love one as a stormtrooper. :cool:

Google search stormtrooper pepakura files. :D

[AsignObservatory]

Coming together...

http://i.imgur.com/RiAa3uo.jpg

[ameerat42]

Who's that mortal standing next to you, Borg? --Er, Bazza?
Irrelevant! Species 10248, astronomical aficianado. He will be assimilated!
(Like I now) Am. (Resistance was futile.)

[AsignObservatory]

Who's that mortal standing next to you, Borg? --Er, Bazza?
Irrelevant! Species 10248, astronomical aficianado. He will be assimilated!
(Like I now) Am. (Resistance was futile.)

LOOL! :lol:

[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.
http://i.imgur.com/3J8KcKq.jpg

2. Rough filler application continues around the left side.
http://i.imgur.com/nCT7w3s.jpg

3. Now getting a bit of an idea of symmetry for adjustment.
http://i.imgur.com/zLrqXQn.jpg

[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.

http://i.imgur.com/qrKJXWO.jpg

http://i.imgur.com/ux8JwVr.jpg

The sanding continues.

http://i.imgur.com/jZwzu32.jpg

[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.

http://i.imgur.com/zPq4ra9.jpg

[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.

http://i.imgur.com/J9CtCUt.jpg
http://i.imgur.com/JvF6NTM.jpg

[AsignObservatory]

Right arm assembled, ready for hardening with resin.

http://i.imgur.com/723nTE5.jpg

[AsignObservatory]

Trial fit. Looking alright so far....

http://i.imgur.com/Hi6AyMp.jpg

[tcdev]

Is there anything you cant do???
I hate people like you, Barry! :D

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. :o

[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.
http://i.imgur.com/JoUFjGX.jpg

Checking for proportions, this thing is looking MEEEAANNN! Can't wait to put it on!
http://i.imgur.com/VHyMvFZ.jpg

[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..... ;)

http://i.imgur.com/81S6Ibu.jpg

[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.

http://i.imgur.com/W2qyLEP.jpg

[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!!!:lol::lol:

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!!!:lol::lol:

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! :lol2:

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.

http://i.imgur.com/fEbBJRb.jpg

[AsignObservatory]

Got the left arm assembled and started work on the gauntlets.

http://i.imgur.com/yUJxKR4.jpg

http://i.imgur.com/VwYPZf6.jpg

http://i.imgur.com/7xOvWSv.jpg

[AsignObservatory]

The wee hours of the night when everyone else goes to bed is my time. My time to relax and be nerdy. I got the left hand fully assembled tonight and this morning. The good camera is out in the observatory and it's too darned cold to go out and get it, so a phone-camera shot it is.....

http://i.imgur.com/IFchH2c.jpg

[ricktas]

If Iron Man thinks it is top darned cold out..what chance is there for the rest of us surviving winter? :p

[AsignObservatory]

If Iron Man thinks it is top darned cold out..what chance is there for the rest of us surviving winter? :p

That's because I haven't got as far as solving the icing problem.....

[flyonthewall]

Wow. The amount of hard work that has gone into this is amazing.

[mikew09]

This definitely an obsession but I am lovin it due - keep it posted as I cant wait to see the end result

[AsignObservatory]

Time for some creative photography.

I set-up the work so far in my studio and prepared the lighting, height, distance etc. I then donned what I could and played with the result in Photoshop to bring in some colour that I'm not yet ready to paint on.

It's good to just get a little bit of an idea of where I am headed with the suit. It's also good to see it all together so I can check proportions etc.

1. Setting up studio lighting.
http://i.imgur.com/JH0n43O.jpg

2. All the bits taped together in position.
http://i.imgur.com/hbuj5xB.jpg

3. Fun with Photoshop!
http://i.imgur.com/I5CFwjR.jpg

[AsignObservatory]

and with a touch of gold...

http://i.imgur.com/a6KplC0.jpg

[ricktas]

Wonder how many, like me, are awaiting the day we click this thread for an update and see you standing there, in it, finished and ready to fight crime!!!

Looking great so far...but hurry up.. :lol:

[Tommo1965]

very cool..I expect the kids will love it.....cause Id love it too!

with a bit of discret shaving of the old whiskers you will get away with as a passable Tony stark

[AsignObservatory]

Got busy building the cod-piece.

Front
http://i.imgur.com/qeSs2OG.jpg

Back
http://i.imgur.com/CrMTWEs.jpg

[outstar79]

Hope you measured the cod piece right Baz! Awesome job so far mate, we wait with bated breath until our whole hero is unveiled! :cool:

[AsignObservatory]

Hope you measured the cod piece right Baz! Awesome job so far mate, we wait with bated breath until our whole hero is unveiled! :cool:


Something I should have done in the very beginning -

MAKE A TAPE DUMMY!

Fitting, modifying and adjusting the suit needs to be done accurately and doing it on my own body is darned near impossible.

With a tape dummy to my exact proportions, I can build and modify the whole suit on it and have it all fit together exactly, being sure that it will fit me when done.

I watched some U-tube tutorials by a guy called STEALTH on how to make this.

First a supporting frame has to be made out of PVC pipe. Then it's just a matter of putting on some thin clothes that you don't mind cutting up, tape up the sleeves, ankles and waist then get an assistant to wrap you up like a mummy in PVC Duct tape.

I couldn't believe how good it made my back feel... I might have to tape up my back every day before a start swinging the chainsaw at work!

Once covered from ankle to neck, then it's a matter of the assistant cutting the silver suit off - just enough to wriggle out of it, which can be slow and tedious, but taking your time is key.

Next insert the skeleton support and start to tape up the cuts, leaving the torso open until last. Stuff the whole suit with newspaper, rags, sheets, foam or whatever you have and pack it right out. The tape won't stretch beyond how it was while you were wearing it, so your form is retained.

I've run out of tape (used three rolls of 30 metres) so I'll have to pick up another roll tomorrow and stuff the suit as soon as possible.

This is going down as one of the top few weirdest things I've done.....

http://i.imgur.com/xOR5bJT.jpg
http://i.imgur.com/ilgb69N.jpg
http://i.imgur.com/4OZHUTC.jpg
http://i.imgur.com/l8wrHNh.jpg
http://i.imgur.com/i8X0YLP.jpg

[AsignObservatory]

Tape dummy complete with some of the armour mounted on it.

http://i.imgur.com/Lpd802x.jpg

[ving]

Got busy building the cod-piece.

Front
http://i.imgur.com/qeSs2OG.jpg

Back
http://i.imgur.com/CrMTWEs.jpgspunky pants! :p

[outstar79]

:lol: Love the Anit-swoon safety square! :D Certainly wouldn't want to tape that piece up! :eek:

[AsignObservatory]

:lol: Love the Anit-swoon safety square! :D Certainly wouldn't want to tape that piece up! :eek:

Certainly not!

Here's one hip-pod I finished pepping tonight.

http://i.imgur.com/BmHOgOY.jpg

[Duane Pipe]

:lol::lol: The tape Dummy.. How the hell do you find the time to do all this stuff Barry. Its going to be well worth it in the end I'm sure. I am Iron Man from Black Sabbath....

I would like to build a 1/4 scale composite rc spitfire Barry, fuselage mainly, how do you think Pepakura would go for a one off or even a plug. Keep up the good work:th3:

[para]

thats awesome good job

[AsignObservatory]

:lol::lol: The tape Dummy.. How the hell do you find the time to do all this stuff Barry. Its going to be well worth it in the end I'm sure. I am Iron Man from Black Sabbath....

I would like to build a 1/4 scale composite rc spitfire Barry, fuselage mainly, how do you think Pepakura would go for a one off or even a plug. Keep up the good work:th3:

Dave, you can build pretty much anything with pepakura as a starting point. Give it a go I say!


thats awesome good job

Cheers Stu!

- - - Updated - - -

Left thigh work in progress.

http://i.imgur.com/VjJi53o.jpg

[Epoc]

My Ironman crazy young fella has no interest in photography but after I showed him this post, he added AP to his favourites. :)

Fantastic effort Barry and I gotta wonder, do you ever sleep?? ;)

[AsignObservatory]

My Ironman crazy young fella has no interest in photography but after I showed him this post, he added AP to his favourites. :)

Fantastic effort Barry and I gotta wonder, do you ever sleep?? ;)

Only when I'm not awake mate... ;)

Ready for oil!

Well.... nearly...

I have one tread at the top of the stairs left to cut and install. It's a bit tricky because it is surrounded on two sides by thick steel and some bolts, lips, edges etc - lots to custom-cut around to make it fit.

The insulation is back in the walls with every nook and cranny stuffed to keep the temperatures out/in and also a bit of soundproofing.

The bulk of the work is done but there are a couple of gaps that I want to fill and tidy up. Now the wall-panelling can be cut for the stairs and fitted on the walls.

http://i.imgur.com/Rl3M7wr.jpg

Big hole!

As soon as the stairs are dressed, there's the issue of the long drop from the top floor. A bannister needs to be constructed with a gate at the top of the stairs.

Stay tuned for the updates as I get to the task.

http://i.imgur.com/JKrhAN1.jpg

[PhotoPaul]

This is seriously cool! I'll be watching the build with great interest :) Keep up the good work

[Epoc]

I think you posted your last post in your wrong thread Barry. Might be time for a good sleep mate ;)

[Duane Pipe]

I think you posted your last post in your wrong thread Barry. Might be time for a good sleep mate ;)

:lol::lol::lol:

Love the rustic timber:th3:

[Kelz1990]

That looks amazing. Well done :)

[AsignObservatory]

I think you posted your last post in your wrong thread Barry. Might be time for a good sleep mate ;)

Crikey! Good spot mate! Yes, too many 3am bed-times....

[AsignObservatory]

Left thigh assembled. This one was a little more difficult than I expected. For such a large piece it is made of an incredible amount of small parts. Very fiddly cutting and folding on this one.

This is the first part I've made that came with braces to go inside it for shaping. This way I can harden it then cut the braces out and it will retain the correct shape.

I tried it on my leg and it fits perfectly, even allowing for thick and loose tracksuit pants, later to be replaced by bicycle long-johns and the padding inside the armour.

http://i.imgur.com/lBLuxnk.jpg

http://i.imgur.com/36aysnK.jpg

[AsignObservatory]

I just laid the cod on the floor with the thigh under it and hip-pod attached to check for scale. Looks ok so far.

http://i.imgur.com/FSe1cru.jpg

http://i.imgur.com/COuccGq.jpg

[AsignObservatory]

Shin assembled.

http://i.imgur.com/afY1Fkf.jpg

http://i.imgur.com/R8Tz8Pi.jpg

http://i.imgur.com/7AI7SXb.jpg

[Debra Faulkner]

Brilliant work. Very inspiring to see a project coming together in this way. :th3:

[AsignObservatory]

Thanks mate.

Checking for fit. By the time I get the inside fibreglassed and padded, then the undersuit - there won't be much room left in there. Should be a snug fit.

http://i.imgur.com/ZUr5c6w.jpg

http://i.imgur.com/ctaU87s.jpg

[AsignObservatory]

I spent a few hours immersed in toxic organic fumes today in the shed, while sleet and snow outside kept the resin temperatures low.

I painted the inside and outside of thigh and shin with resin, then bit at a time - poured in the slush-cast.

One thing I would do in future, is tape the knee joint together before doing anything. I was lucky that the slush-cast was still a bit pliable so I could bend and squeeze the knee together then tape them in place while it sets properly. Before I line the inside with fibreglass matt, I will do the same again.
http://i.imgur.com/JcUpII0.jpg

[AsignObservatory]

Now the inside is slush-cast and the knee is taped tight into position, today I started laying in the fibreglass mat. Thigh and ankle flaps done.

I also found a broken headlight and thought the reflector inside would be great in the chest behind the arc-reactor LED's. I'll trim it to shape and see how it looks.

http://i.imgur.com/IvR4hQQ.jpg

http://i.imgur.com/1XJKO85.jpg

[AsignObservatory]

I started working on the headlight reflector today to go behind the front face of the arc reactor. There looks to be a 50/50 chance I might like it or throw it away.

Gave the collar plates another application of filler, sanded than painted. I think I'll keep going until they are smoother, but they are looking ok so far. Getting it made is easy. Getting it perfect.... well that's another story. It's harder than you might think.

I've been having trouble articulating the elbow joint. It has broken already in two places. Fibreglass is hard, but also brittle. Now I've fabricated some reinforcing aluminium bar to join the upper and lower arm. It's a lot of fiddling about.

http://i.imgur.com/KRlIPhq.jpg

http://i.imgur.com/OVhGo1b.jpg

http://i.imgur.com/maT3iOa.jpg

[AsignObservatory]

It's been a while since I've had any time to work on the suit, but today I had a little time to put all I've done so far together on the tape dummy to see how it all sits.

I have some major adjustments to do on the waist/cod piece. I'm thinking of cutting the rigid sides off the waist/abs and replacing them with roam rubber. For the cod, all I need to do is cut and extend it slightly to give it a bit more diameter around the hips until the hip-pods are vertical.

At least it's still in the paper stage so that's not difficult.

http://i.imgur.com/eddY8fD.jpg

http://i.imgur.com/0vxuxVy.jpg

[michaellxv]

A few too many rainy days where you are?

[AsignObservatory]

A few too many rainy days where you are?

Need more rainy days so I can finish this sucker!

[macmich]

baz
what is your plan for the suit when the projects finished
or whats the next project
cheers macca

[AsignObservatory]

baz
what is your plan for the suit when the projects finished
or whats the next project
cheers macca

Top secret dude. ;)

- - - Updated - - -

I got nearly a whole day to myself today and with no observatory to build anymore, it was off to the workshop with me!!!

One of the problems I've had with the suit is in the scaling and fitting. The suit is not anatomically correct for a human being, so even if you get the right height and width, some parts just narrow down far too much.

The waist is as such.

The rigid sides that go from lumbar armour around to abdominal armour have been sitting very uncomfortably over my hips and are about 2 inches in diameter too small so it's very tight.

To solve this, I cut the rigid sides off and replaced them with foam rubber mat.

Once I got that done I did a quick test fit. Now that's done I can move onto the cod piece and widen that around the waist too.

http://i.imgur.com/v1HYKNQ.jpg

http://i.imgur.com/PxHpKYO.jpg

http://i.imgur.com/XDKhzeI.jpg

http://i.imgur.com/m1nPTjz.jpg

http://i.imgur.com/MsYUVuL.jpg

http://i.imgur.com/mjxbusy.jpg

http://i.imgur.com/oU0ftvB.jpg

[AsignObservatory]

Lots of concurrent bits to do while waiting for the filler to set on other parts.

The internal chest/back brace only needs filling and sanding where it shows so I'm not wasting any more bog where it doesn't need it. I will, however, put another layer of fibreglass matt on the inside to make it as rigid as I can.
http://i.imgur.com/Fryny0Y.jpg
Where I have used foam around the waist, today I used a wood-burning soldering iron to melt in the joints between the rib plates. I placed a big elastic band around the whole piece to see if I can pre-shape it a bit before I put some heat into it later.
http://i.imgur.com/mLx0cQ2.jpg
Getting some more sanding and detailing done on the chest/back. The back is very detailed and has a lot of raised and sunken sections to negotiate with body-filler and the sanding block.
http://i.imgur.com/UfHCcPj.jpg
Finally got onto a finishing sand of the abdominal plates so I could give it a paint. The ankle and achilles control surfaces are also on the painting block.
http://i.imgur.com/f6tC4Fs.jpg

[AsignObservatory]

Got into some serious finishing today. I bought a can of paint that had a GOLD lid, but the colour label said ORANGE. I asked the paint salesman which was correct and he said the colour of the lit was correct.

Looks like he was wrong.

http://i.imgur.com/tnyvu3v.jpg

[AsignObservatory]

FINALLY!! I found a gold paint that satisfies!

http://i.imgur.com/SnPGjcV.jpg


http://www.youtube.com/watch?v=qnp44YTjtiE

[AsignObservatory]

Now I've got the colours right, I've sanded down the helmet again to prepare for the colour upgrade. Before I do that, I want to improve the faceplate hinge animatronics. I visited an engineer friend of mine and he gave me a solve, but it's something that needs to be done in a machine shop with precision lathing and milling.

Whilst that's great, it departs from the theme of being achievable in the average blokes shed, so I am opting for a solve of my own, repositioning my servo motor and using an aluminium push-rod.

Until then, I'm going to hold off re-painting the helmet.

http://i.imgur.com/7l6vUl5.jpg

http://i.imgur.com/95YxSmA.jpg

[AsignObservatory]

Here's the idea constructed in some cardboard to see if it's going to work. I've located the point of mechanical advantage, done the calculations on the servo's torque and load to move. This might actually work!

There's just enough room along the jaw to fit the servo sideways but I'll have to put something between the armature and my cheek, lest I rip out a few of my designer facial hairs.....

http://i.imgur.com/LvQpGEk.jpg

[AsignObservatory]

Fabricated a push-rod from some aluminium round bar. Servo push-pulls it fine. It's a bit squeezy in there so I bent the bar to contour my cheek a bit better.

http://i.imgur.com/Sd2bCda.jpg

http://i.imgur.com/eqIf5UO.jpg

http://i.imgur.com/YhIsD0a.jpg

[enseth]

Hope your not expecting to be too comfortable when you wearing this outfit:)

[AsignObservatory]

Hope your not expecting to be too comfortable when you wearing this outfit:)

It's not likely, but then I am fairly inventive when it comes to padding....

[AsignObservatory]

Got a bit done this afternoon. The internal chest/back-brace needed to be filled and sanded where it shows under the suit.

I also laid a second layer of fibreglass inside this one to give it extra strength/stiffness.

Here's a quick test-fit now that it's been shaped. I've traced a pencil line on it so I can take it out, give it a hit with spray-putty then a final sand before painting.

http://i.imgur.com/0kCqpjs.jpg

[AsignObservatory]

I got a few hours over the last couple of days so I got a bit done.

I'm still running into troubles with paint. I found the gold I am happy with and thought a clear coat over the top to protect it would be good. Today I sprayed an acrylic clear coat over the gold and it turned it a dull gold almost brown. GAHHHH! :mad:

Anyway, back to the drawing board with paint I guess. I could just leave the gold unprotected, but it means it will wear quicker.

Once I tested it all for fit and look, I have made a bit more progress on shaping the back. This is probably the hardest part of the suit as there are so many recesses. Hard to get sandpaper in there.

1. Undercoating the chest/back-brace with gold

http://i.imgur.com/08OCdNu.jpg

2. Overcoating with the anodised red. (only the smoothed areas will show outside the suit)

http://i.imgur.com/xHC4z2D.jpg

3. Paint selection

http://i.imgur.com/tkiquUj.jpg

4. Clear over gold on the right. Looks crap.

http://i.imgur.com/9QAuTJn.jpg

5. Looks good together

http://i.imgur.com/DYZeemq.jpg

6. Continuing on the back

http://i.imgur.com/URMRYiv.jpg

[ameerat42]

About the first 2 pics here. So that's what a "saw back" means!?!:D

[AsignObservatory]

About the first 2 pics here. So that's what a "saw back" means!?!:D

Coincidentally enough, for the last couple of months I have had a very saw neck....


I buffed and polished the collar plate with the clear lacquer on it. (The one on the left) It makes it highly glossy, but still hasn't restored the original shine of the gold paint underneath.

http://i.imgur.com/ejRr4uC.jpg

Meanwhile, I've been tinkering with the faceplate mechanism. I built a dam out of tape, wrapped the servo in paper and poured a rondo mix in to harden around the motor. The mechanism works now, with a bit of tweaking/tidying to go to get it smooth. I'll put a short video on you-tube once I'm happy with it.

http://i.imgur.com/gEnPlNw.jpg

[AsignObservatory]

Faceplate mechanism finally working!

Video (http://www.youtube.com/watch?feature=player_embedded&v=HaBs2XUU1w8)






.

[outstar79]

Hoho mate - that works sweet!! Really can't wait until all the teasing is over and we see Iron Man in the "flesh"! :D

[AsignObservatory]

Thanks Adam.

Here's tonight's work.

Eyes AGAIN. I acquired a sheet of thick perspex in opaque white so I cut the eye shapes and put them in the oven until they were soft enough to bend and contour inside the helmet.

Next, I found some hex-pattern steel mesh on the front of some old speakers. I cut them to shape for the eyes too. The vision through them is pretty good. If I do use the perspex I will glue them in with a gap at the bottom to see through. Otherwise I might find some good LED's to put in there on their own instead.

Glued them in with hot glue, taped them up and painted the whole helmet in the shiny gold acrylic. Once that's dry, I'll mask off the faceplate and lip then paint the rest of the helmet the anodised red over the gold. Should come up pretty stunning.

http://i.imgur.com/nGJrsQh.jpg

http://i.imgur.com/9Bb3xrx.jpg

http://i.imgur.com/BtVsLNh.jpg

http://i.imgur.com/P3PERSv.jpg

http://i.imgur.com/4ZBnZaW.jpg

[AsignObservatory]

Got a bit of painting and detailing done today.

http://i.imgur.com/g0FxGZq.jpg

http://i.imgur.com/0leAhGM.jpg

http://i.imgur.com/5yicVOb.jpg

[AsignObservatory]

Just for fun....


http://www.youtube.com/watch?v=48NI9wwdGpY

[AsignObservatory]

I've been working my dodgy electrical skills for a couple of days getting in these 180 Lumen LEDs behind some opaque perspex. Vision is limited, but I can still see what's in front of me.

The lights have kill switches inside the helmet, as well as contacts on the faceplate to cheek that activate the eyes once the faceplate is down.

Still having problems with the faceplate mechanism stripping the plastic gear on the servo though. I feel some superglue is needed....

I'm ready for the padding now.

http://i.imgur.com/bBD735M.jpg
http://i.imgur.com/ZD8f2oR.jpg
http://i.imgur.com/0S2R7Sf.jpg
http://i.imgur.com/eK9yE23.jpg
http://i.imgur.com/8exmIaS.jpg

[Duane Pipe]

Looking great:th3: Man you don't do things by halves...
I like the servo hack for the face plate Barry, Without getting to tech Is it ran with radio gear:confused013

[AsignObservatory]

Looking great:th3: Man you don't do things by halves...
I like the servo hack for the face plate Barry, Without getting to tech Is it ran with radio gear:confused013

No not yet. I'm thinking of some voice regognition commands later, but that's waaaaaay down the track.

[mikew09]

Hey Bazza, I caught part of a show on the tele about man caves or something and there was a bit on a fella that has his own observatory and telescope in his front yard. I am thinking wow that is pretty cool and then the segment says about this fella also making his own Iron Man suite. Which progress I have been following by the way - very cool stuff.
Put two and two together I immediately think, hmm, is that bazza from the AP site.

So, was that segment on the tele you mate or just a coincidence?

Cheers,

Mike

[AsignObservatory]

Hey Bazza, I caught part of a show on the tele about man caves or something and there was a bit on a fella that has his own observatory and telescope in his front yard. I am thinking wow that is pretty cool and then the segment says about this fella also making his own Iron Man suite. Which progress I have been following by the way - very cool stuff.
Put two and two together I immediately think, hmm, is that bazza from the AP site.

So, was that segment on the tele you mate or just a coincidence?

Cheers,

Mike

There's the very slim, miniscule tiny chance it was me, yes mate.... ;)

I've been working on one of the shoulder bells this week.

1. First coat of filler to bulk it out.
http://i.imgur.com/I1cAdxz.jpg
2. Starting to shape and smooth as layers are applied and sanded.
http://i.imgur.com/1FpjGkv.jpg
3. Spray putty and a sand for the finer holes.
http://i.imgur.com/lnCgU0v.jpg
4. Primer filler and a sand in preparation for the final coats.
http://i.imgur.com/KeuQL4C.jpg
5. Undercoat of metallic gold.
http://i.imgur.com/wvX2vSw.jpg
6. Final coat of anodised red over the gold. Sweet!
http://i.imgur.com/UMwYcXR.jpg

[AsignObservatory]

Shoulder bell fitted. This thing is starting to scare me.....

http://i.imgur.com/Vv5Q2lF.jpg

[AsignObservatory]

I've really been putting in the hard yards with the chest and back piece lately. Up until today it was one piece and impossible to get onto the tape-dummy or onto my own body. I've been dreading this bit.

So today I installed some heavy plastic buckles on the inside, fibreglassed them in position then cut the pieces apart right on the join of the buckles.

1. Male buckle installed on the back piece at rib-level

2. Female buckle installed on chest piece at rib-level

http://i.imgur.com/Ta5mk0L.jpg

http://i.imgur.com/8wYaT5M.jpg

3. Preparing for painting!
http://i.imgur.com/jXKRRNH.jpg

Today I started on filling the hip pods with car-filler and finally started painting the chest and back.

http://i.imgur.com/1q3CznZ.jpg

http://i.imgur.com/1i7WryS.jpg

[AsignObservatory]

1. Another test-fit before final coats on the chest piece. Nothing is secured where it should be properly yet, hence the displaced shoulder bell.
2. Chest and back painted. Arc reactor fitted and powered up.
3. The top half of the suit so far. Lots to start fixing together now, padding out the inside and adding all the attachment points to lock it all together.

http://i.imgur.com/1OwMyJI.jpg
http://i.imgur.com/0YckYkY.jpg
http://i.imgur.com/WXs0Ctu.jpg

[AsignObservatory]

1. Problem with cavities in the papercraft solved by cutting away some paper and filling with resin.
2. Going to work on the arms.

http://i.imgur.com/pBCkNpD.jpg
http://i.imgur.com/nVkk3gl.jpg

[AsignObservatory]

Hip pods done. Working on an arm now.

http://i.imgur.com/bm6pel2.jpg

[AsignObservatory]

Masking off the bicep for painting.
http://i.imgur.com/zRDUrHw.jpg
Upper arm and bicep painted.
http://i.imgur.com/PDIOcUm.jpg
Articulating the elbow joint.
http://i.imgur.com/fqBGieC.jpg
http://i.imgur.com/l60W1Tf.jpg
Testing for fit and range of motion.
http://i.imgur.com/BBddSBe.jpg
A couple for fun.
http://i.imgur.com/fcDoSeJ.jpg
http://i.imgur.com/82GILmv.jpg

[AsignObservatory]

Today I did my best to complete the articulation of the right arm. The aluminium is screwed into the shell on the inside then covered with fibreglass mat.

As I had leftover resin I started hardening the left arm on the mannequin.

http://i.imgur.com/MrKjfrP.jpg

http://i.imgur.com/AInfZtO.jpg

[outstar79]

That is looking really impressive now Baz - you need a selfie outside Parliament House when you're finished! :lol:

[AsignObservatory]

That is looking really impressive now Baz - you need a selfie outside Parliament House when you're finished! :lol:

but would it really be a selfie? Hmmmmmm....

[algywt]

That's so ridiculously cool, keep it up, and make sure you update us when it's done

[AsignObservatory]

Padded the insides of the armour today to stop the layers from scratching each other where they overlap. After that, I used socket-head cap-screws to bolt the pieces together. Another quick test fit on me, then back on the mannequin with all the parts.

http://i.imgur.com/V72VLHZ.jpg

http://i.imgur.com/QLuJepd.jpg

http://i.imgur.com/gtNSENU.jpg

http://i.imgur.com/TM0dlds.jpg

http://i.imgur.com/xiMcKnV.jpg

[Photographystudies]

Thats really impressive. Have you thought about working for Stan Winstone?

[AsignObservatory]

Thats really impressive. Have you thought about working for Stan Winstone?

If he pays well, hook me up!

[AsignObservatory]

Jarvis?
http://i.imgur.com/B5e6LlO.jpg

Jarvis!?
http://i.imgur.com/vQGom9Q.jpg

Stoopid compooter....
http://i.imgur.com/g8Jf4uR.jpg

Ahhhhhhhhhhhhhhh.....
http://i.imgur.com/Y2GTqY4.jpg

[Tommo1965]

LMAO..thats funny as Bazza ...suit looks great mate

[AsignObservatory]

LMAO..thats funny as Bazza ...suit looks great mate

LOL! Onya Steve.

Just for some camera fun and to get the finished bits out of harms way in the shed.

http://i.imgur.com/QtZR6OE.jpg

http://i.imgur.com/GubtWjf.jpg

http://i.imgur.com/STZuIyn.jpg

http://i.imgur.com/ribcLRG.jpg

[skggetit]

Amazing stuff. Am very impressed and in awe of what you have done so far. Looking forward to the entire suit.

[danny]

Baz, I think when you finish you will have the power to call the biggest AP meet ever!!

Cheers
Danny

[ROA44]

And watch out if you don't accept. :lol2:

[AsignObservatory]

1. Getting the final fitting done on a half-finished suit and preparing for it's first night out in public!

http://i.imgur.com/qaxp8Vp.jpg

2. Only a week to go before the suit goes out in public. Cleaned the shed, organised the benches, got all the fibreglass and bog, paint, sandpaper, files, hot-glue and more, ready to get into some serious overtime this week to get as much done as possible. I at least want to have the whole upper-body finished. No time for the legs. Oh well, at least I'll be able to sit down at the party.

http://i.imgur.com/z60xPRd.jpg

- - - Updated - - -

1. Getting the final fitting done on a half-finished suit and preparing for it's first night out in public!

http://i.imgur.com/qaxp8Vp.jpg

2. Only a week to go before the suit goes out in public. Cleaned the shed, organised the benches, got all the fibreglass and bog, paint, sandpaper, files, hot-glue and more, ready to get into some serious overtime this week to get as much done as possible. I at least want to have the whole upper-body finished. No time for the legs. Oh well, at least I'll be able to sit down at the party.

http://i.imgur.com/z60xPRd.jpg

[ausfitter]

Who needs the legs on the Iron Man suit when you have Army PT shorts hahahaha

[outstar79]

Who needs the legs on the Iron Man suit when you have Army PT shorts hahahaha

:lol: was just thinking that!

[AsignObservatory]

I love my Army PT shorts. I'll wear them until there's no material left!

Day one of 1 of 6 - got a couple of hours in the shed today so I've been slush casting and putty-filling madly to get done by party time on day 6. Slush casting completed on shoulder bell, bicep and most of left forearm. Bit of filling done on shoulder bell.

http://i.imgur.com/JC6UGSJ.jpg

[AsignObservatory]

1. A fair bit of progress today. Lots of fibreglassing curing in the shed. In the meantime, the neck piece has been a problem as the rigid fibreglass one offers no movement, plus I can't get my head through it. This new EVA foam one does the trick.

http://i.imgur.com/1PS49D3.jpg


2. Fitting with alternate-locking velcro plates.

http://i.imgur.com/ZNV84Z8.jpg


3. With helmet. Making some return springs to close the helmet behind my head. More on that bit later.

http://i.imgur.com/pojaxuo.jpg

4. Neck piece painted with vinyl spray for flexibility.

http://i.imgur.com/vvqBe1K.jpg

Four days to go!

[AsignObservatory]

3 days left.....

1. Got the neck installed.

2, 3 & 4. Got the left arm hardened, jointed and have started filling.

5. Got a shoulder bell hardened, filled and sanded. Just put the undercoat on it.

6. Got the waist sorted out, just got to go down town and get some velcro to finish it. I'm having a quick lunch now then back to the shed for some serious sanding muscle.

http://i.imgur.com/krZR9tr.jpg

http://i.imgur.com/bGDnL6o.jpg

http://i.imgur.com/1R2nK9T.jpg

http://i.imgur.com/j1yEpc0.jpg

http://i.imgur.com/YNaypP0.jpg

http://i.imgur.com/GJKCbhJ.jpg

[AsignObservatory]

Abdominal and waist armour fitted. Velcro to pull in my fat guts and a couple of nylon straps to hold it up.

http://i.imgur.com/tWDHXDZ.jpg

http://i.imgur.com/juqADMg.jpg

[AsignObservatory]

Tonight's the night! I worked on the suit right up until 5am this morning. Last bit of painting and fitting happening now.

Here's the waist setup finished.
http://i.imgur.com/l8tNbfV.jpg

http://i.imgur.com/lwzEHGW.jpg

Very rushed job on the arms to get them done. They are painted now and baking outside in the sun.

http://i.imgur.com/rsHiPxZ.jpg

http://i.imgur.com/T4ywrZM.jpg

http://i.imgur.com/diSjFaq.jpg

http://i.imgur.com/hkOnQwo.jpg

- - - Updated - - -

While that was happening, I fitted straps and clips to the inside of the shoulder bell and bolted the plastic receiver to the inside of the shoulder.

http://i.imgur.com/NgCM7uq.jpg

http://i.imgur.com/RYoArbO.jpg

http://i.imgur.com/LP26i4G.jpg

http://i.imgur.com/ozTW29F.jpg

That's the top half complete enough to wear tonight. That's if I don't collapse from exhaustion first....

[AsignObservatory]

Here's some failure feedback for those attempting similar. I've just got my brother to come around ten minutes ago to help me put it all on and see what mobility I have and make any adjustments. Might have a few holes to drill and bolts to install. I can't move my arms much because the shoulder bells jam on the chest piece.

The suit is not anatomically correct in the Pepakura files, so even though my height and width measurements were entered in the scaling software, the proportions just don't work.

It's wearable with limited movement, but after the initial fuss at the party dies down, I'll take the arms off to relax.

Like the first observatory, the second will be a huge improvement. There are so many things I would do different, but you have to try it all out to find out how.

I'll still finish the rest of the suit. It still makes a great statue in the observatory.

http://i.imgur.com/aIIGKGD.jpg

http://i.imgur.com/7fpKUnd.jpg

http://i.imgur.com/7IxyqDL.jpg

[AsignObservatory]

First night out in the suit (top half) a raging success. Hanging out with Mr Riddick and the Green Lantern, among many others. Lots of good clean fun.

A few things I learned that are very useful:

1. The suit, while difficult to move my arms, was very comfortable and kept me quite cozy in the cool night air.
2. Visibility in the helmet was difficult in the dark so they will need work. Helmet was very comfortable and having a hinged faceplate was fantastic.
3. The upper body is too bulky so the next one will have to be tailored in under the arms to allow arm movement.
4. Need to find a better way to attach the arms to the chest-piece.
5. Very happy with the waist setup. Easy on , easy off and flexible. Still, I want to rebuild it in aluminium and have it bolt together for cosplay.
6. Will re-do the neck piece in RED eva foam, instead of trying to paint blue EVA with red vinyl spray. It still cracks and flakes.

Aluminium suit.... here I come.

http://i.imgur.com/9n0sAEs.jpg

[mpb]

And now you are featured on the Sydney Morning Herald online site. Well done.

[mudman]

And now you are featured on the Sydney Morning Herald online site. Well done.

and the canberra times

[AsignObservatory]

ASIGN Observatory II on the front page of The Canberra Times today.

http://www.canberratimes.com.au/technology/sci-tech/canberra-stargazer-brings-astronomy-to-the-young-20140214-32rt2.html

[AsignObservatory]

Two minutes of fun with the camera and Iron Man's new ride.

http://i.imgur.com/yLojkQL.jpg

http://i.imgur.com/UGPohzH.jpg

[ameerat42]

Baz. I saw you on "Better Gnomes and Gargoyles" the other night. :D I think it was a repeat, but 1st time I saw it.
Strange, too, as I don't usually watch the show.
Am.

[J.davis]

Very nice 'flying fridge' Baz. Looks to have been well looked after.

[vinhtee]

Just stumbled onto this thread. Such dedication and precision. From an engineering point of view, some of the best home work I've ever seen.

[nimrodisease]

Nice ride! And cool idea for those shots..

[AsignObservatory]

Cheers guys. You'' be able to say in years to come, "I knew him before he was famous!" :lol:

Finally made a start on my new METAL Iron Man suit. Found an old aluminium sign about 2mm thick. Tracing up templates now.

The plan is to fit card templates over what I have built so far, then flatten them out and trace them onto sheet metal. Cut slots into key points in the sheet to facilitate the most curve, weld them shut, then use an egg-mallet and other shaping tools and hammers to fashion the shape better.

http://i.imgur.com/1gXqsKX.jpg

Getting ready to transfer templates to the next gen of Bazza's Iron Man build onto metal plate armour.

http://i.imgur.com/mSeASJJ.jpg

Ready to start cutting and shaping. Insert mad scientist manic laughter here...

http://i.imgur.com/s3RPVIj.jpg

Next cardboard template to be traced onto sheet metal. Anyone in Canberra got a TIG welder?

http://i.imgur.com/uPh9QmI.jpg

- - - Updated - - -

1. Metal cut out and ready to beat to death with a peening hammer. This will be fun. I've done all kinds of metalwork before, but this is new to me. Let's see how we go.

http://i.imgur.com/0KVjZBO.jpg

2. A few minutes with the peening hammer on a wooden block.

http://i.imgur.com/GLwgGoO.jpg

3. 1/2 an hour of metalshaping and it's looking promising. Certainly a lot quicker than the pepakura/bondo/fibreglass method.

http://i.imgur.com/0fLIS97.jpg

4.
Looks OK. In hindsight, I would not cut the slots to help shape the crown. Aluminium is malleable enough to form a bowl on it's own. The hazards of learning for yourself.

http://i.imgur.com/1NSu7pD.jpg

[Roosta]

I also like the posing in front of your shots hanging proudly on the wall (gratuitous plug. LOL) Iron Man and the Milky Way..

[AsignObservatory]

Right shin and boot done. A few mods to do before transferring templates onto aluminium.

http://i.imgur.com/jTMLvYR.jpg

- - - Updated - - -

I've had a bit of time at night to get a fair bit done with all this rain.

Funny thing is, I've printed all this off at the default scale for a 6-foot tall male, even though I'm 6'2". All this gym work I've been hard at for the last few months seems to be paying off as the suit is smaller than my last but I seem to fit into it perfectly - especially my midriff which has trimmed down a lot from my middle-aged spread.

Building in cardboard is a brilliant precursor to sheet metal, as it's shaping properties are similar, being semi-rigid and prone to buckling if you do it wrong.

http://i.imgur.com/dBhFGEZ.jpg

http://i.imgur.com/y3hfqn8.jpg

- - - Updated - - -

Today I've been working on the thigh. Perfect fit. Obviously it's cardboard so distortion will always happen when you put it on and move around, but once it's done in aluminium it won't be difficult to get each part aligned permanently.

http://i.imgur.com/McB0bld.jpg

http://i.imgur.com/oW98E0q.jpg

- - - Updated - - -

Chest and back inner-brace done.

http://i.imgur.com/CE6yhMY.jpg

http://i.imgur.com/mbsuxJy.jpg

- - - Updated - - -

Collar plates done.

http://i.imgur.com/YR4RtNf.jpg

- - - Updated - - -

http://i.imgur.com/2K76Qit.jpg

- - - Updated - - -

Cod piece done and added to the rest.

http://i.imgur.com/BKB4S9M.jpg

http://i.imgur.com/jrlHYKi.jpg

- - - Updated - - -

Cardboard showing me already where I will need to expand, modify or trim a few things before cutting out aluminium templates.

http://i.imgur.com/qIHdjdl.jpg

http://i.imgur.com/7YNQwPV.jpg

- - - Updated - - -

Back armour almost done. It's nearly 2 am though so it's time for some zzzzzzzzzzz.... I'll see if I can finish it tomorrow.

http://i.imgur.com/ajHsoc7.jpg

- - - Updated - - -

For those of you who have been asking how I am going to colour my aluminium Iron Man suit, I won't be painting it - I will be anodising it. Here is a sample.

http://i.imgur.com/B47hXyy.jpg

Back assembled. This was actually way easy to put together. I was dreading it thinking it was going to be complicated.

http://i.imgur.com/HfqKlN5.jpg

- - - Updated - - -

Back all painted up. I know it's only cardboard, but will still finish up as a nice statue while I build the aluminium one.

http://i.imgur.com/qCc2GOy.jpg

http://i.imgur.com/Rgootov.jpg

http://i.imgur.com/53vLnLW.jpg

- - - Updated - - -

Neck seal assembled.

http://i.imgur.com/Y3MTFDo.jpg

Chest and back fitted together with brace and neck seal, collar plates, abs and cod.

http://i.imgur.com/WDkWgTb.jpg?1

- - - Updated - - -

1. All the bits for the helmet cut out ready for folding and gluing.

http://i.imgur.com/wSv5O9M.jpg

2. Helmet partially assembled. Too tired to finish it tonight.

http://i.imgur.com/uuYopM3.jpg

3. Helmet assembled and painted the next morning.

http://i.imgur.com/PSBnq28.jpg

4. Faceplate assembled.

http://i.imgur.com/SecjBAP.jpg

5. Faceplate and helmet. I've got some shaping to do to make it all symmetrical.

http://i.imgur.com/tAJRF1F.jpg

6. Helmet on torso.

http://i.imgur.com/OtTObCh.jpg

- - - Updated - - -

Last night I completed the hip pods and spine.

1. Spine installed.

http://i.imgur.com/2TCniBR.jpg

2. Hip pods assembled.

http://i.imgur.com/9Edvxpz.jpg

3. Hip Pods installed.

http://i.imgur.com/uSKbvtO.jpg

- - - Updated - - -

1. Shoulder bells assembled.

http://i.imgur.com/1NvAfaF.jpg

2 & 3. Shoulder bells painted and fitted.

http://i.imgur.com/YTTPJxr.jpg

http://i.imgur.com/WIv2JhC.jpg

- - - Updated - - -

The pieces are starting to come together nicely. A few adjustments and it's ready for the transfer to aluminium!

http://i.imgur.com/ylm4SUj.jpg

http://i.imgur.com/wSJWnne.jpg

- - - Updated - - -

1. Show me a clean floor and I'll show you no work being done....

http://i.imgur.com/ftjYeNe.jpg

2. A couple of cartons of beer went into this shin.

http://i.imgur.com/mu43gUm.jpg

3. Left leg complete. Got to make another boot out of cardboard tonight to replace the foam trial boot.

http://i.imgur.com/LwF4hOf.jpg

- - - Updated - - -

1. Last boot. Practice makes perfect. I'm so glad I have approached this incrementally. The fibreglass/car-bog method was good to learn, but messy, expensive and time consuming in the extreme. Doing a boot in foam was also a good learning experience, but still not practical. Finally moving on to cardboard before the aluminium build, each part I make just gets better in quality as I gain experience. This is the third boot I have made and I reckon it's 100% on the first one.

http://i.imgur.com/l3JfKiw.jpg

2. Forearms assembled.

http://i.imgur.com/oCExr05.jpg

3. Articulated handplates assembled.

http://i.imgur.com/COtkYTB.jpg

4. Only the hands left to go now.

http://i.imgur.com/u4tfVRD.jpg

[agb]

Great work AsignObservatory.

[AsignObservatory]

Great work AsignObservatory.

Thank you sir.

[AsignObservatory]

A bit of fun with the camera around the observatory.

1. I reckon I should be able to see Loki coming for miles with this...

http://i.imgur.com/78U8brs.jpg

2. It's a bit bright though...

http://i.imgur.com/wWONZj3.jpg

3. Jarvis, where's the remote?

http://i.imgur.com/7Ls2N78.jpg

4. Brothers in arms.

http://i.imgur.com/Ga4SEPC.jpg

5. The fibreglass one on the right is on a stand so it looks taller.

http://i.imgur.com/IRicfaG.jpg

6. That's right, you just stand over there in the corner and think about what you have done...

http://i.imgur.com/TDPGCGr.jpg

7 & 8. Do I look battle damaged?

http://i.imgur.com/8eXdpa5.jpg

http://i.imgur.com/aOomCJY.jpg

[vinhtee]

Looks beautiful. Is this a complete aluminium build? I'm curious about the mobility of the suit once completed.

[agb]

I hope the beer did not go to waste.

[AsignObservatory]

Looks beautiful. Is this a complete aluminium build? I'm curious about the mobility of the suit once completed.

Thank you sir. I have actually mentioned several times that this is a cardboard build, to be modified for fit before transferring the templates onto aluminium. My last suit made out of rigid fibreglass helped identify many places that hindered mobility.


I hope the beer did not go to waste.

Naturally. :cool:

[AsignObservatory]

Well the hand was a tricky one. So fiddly! I had to modify it a bit and make some of my own parts as this pepakura file wasn't really designed for the medium I am using.

Got it done though in a marathon all-nighter. Nearly 5am and I've been going for ten hours. zzzz....

One to go.

http://i.imgur.com/EjR1vQj.jpg

http://i.imgur.com/K2Onxng.jpg

http://i.imgur.com/vymDQVB.jpg

[AsignObservatory]

1. Last items on the painting rack.

http://i.imgur.com/hznhMB6.jpg

2 & 3. Gauntlet and handplate attached top and palm views.

http://i.imgur.com/l59e9Mn.jpg

http://i.imgur.com/iOSJ4bY.jpg

4. Arc reactor fired up.

http://i.imgur.com/4phc7nt.jpg

5. YAAAYYYY!! It's finally finished! Next stop - Aluminium build!

http://i.imgur.com/2fkjVTU.jpg

Now I'm going to BED!!! For a month.

[nimrodisease]

Epic! Looking forward to seeing progress on the aluminium build.

[agb]

Great job,dedication and really good work.

[AsignObservatory]

Epic! Looking forward to seeing progress on the aluminium build.


Great job,dedication and really good work.

Ta blokes. Here you go then!

1. Prototype three now a bigger fit by 15mm. Much more comfortable. I've modified it so that the bottom plate at the back of the head now swivels up inside the helmet to allow room to put the helmet on, then swivels back down into position behind the head.

http://i.imgur.com/fFStS9Q.jpg

2. Resized helmet on the left 15mm larger than the one on the right.

http://i.imgur.com/zNAwCY1.jpg

3. Aluminium templates marked ready for cutting.

http://i.imgur.com/Lmu11gO.jpg

4. Cutting aluminium templates on the bandsaw.

http://i.imgur.com/5MTMw5n.jpg

5. Cutting with the bandsaw, staying 1/2 millimetre to a full millimetre outside the edge line to be filed flat.

http://i.imgur.com/ROg6gVd.jpg

6. Chin piece cut out.

http://i.imgur.com/ghHETtP.jpg

7. Stitch drilling the shaped hole out, staying a couple of millimetres inside the edge line to be filed flat.

http://i.imgur.com/XMVOywi.jpg

8 & 9 Filing the stitch-drilled holes flat to the edge line.

http://i.imgur.com/3BInU49.jpg

http://i.imgur.com/u6Pkqey.jpg

10. Chin and lower lip pre-assembled, ready for welding.

http://i.imgur.com/kvNRRD6.jpg

11. Chin and lower lip pre-polished. This will make it easier to finish polish once it's all welded together.

http://i.imgur.com/EmHwOoT.jpg

[JJM]

Unreal Bazza, I can't wait to see more updates!

[AsignObservatory]

Unreal Bazza, I can't wait to see more updates!

Here you go then mate! :)

1. Chin, sides, top and one back plate cut and pre-polished.

http://i.imgur.com/ktsa6tx.jpg

2. Beating it into shape using a curved-face rubber mallet and a foam mat on concrete. Got to be careful to hit it in key points and not too much, or it begins to stretch the metal.

http://i.imgur.com/JZqsmFB.jpg

3. For the tighter curves, I re-shaped the end of an old plastic mallet on the grinder.

http://i.imgur.com/d6L1eZQ.jpg

4. Curves looking good.

http://i.imgur.com/1sfclsI.jpg

5 & 6. Temporarily tacked together with a bit of hot-glue to get an idea what needs to be bent more or less.

http://i.imgur.com/tJWf8Oh.jpg

http://i.imgur.com/IbUCh0B.jpg

7. Yep.... Fits.

http://i.imgur.com/resrqAF.jpg

[AsignObservatory]

Faceplate cut and pre-polished.

http://i.imgur.com/udZHpLD.jpg

[AsignObservatory]

I made a few tools today to help me shape the metal for Iron Man.

1. A short piece of an old post, reshaped into a mallet-head with a wide and narrow end, an old broken sledge handle, cut down to make a good handle for the mallet.

2. A thick piece of steel with a slot cut in it at the thickness of the aluminium I am using, then a spanner on the side to provide enough torque to bend the sheet-metal right on the line.

3. Finally, a short but thick piece of steel, shaped on the grinder to act as a battering ram to achieve very tight and precise curves.

http://i.imgur.com/cvdvgSL.jpg

4. These tabs all fold up to form a step to the next piece. The large blank bit in the middle needs to be cut out, but it is best to do that after the tabs have been bent. I'm thinking that instead of these clunky tabs, I will cut them all off and just cut a long flat strip, then curve it into a ring to form the circular step instead.

http://i.imgur.com/X3qWuO3.jpg

5. More helmet pieces cut from aluminium.

http://i.imgur.com/1Y2Z0Ms.jpg

[Steve Axford]

More performance art than photography, but fascinating. Keep it up.

[agb]

Love these progress reports. Are you going to get tired of all the filing you are going to have to do to complete this? I hope not as I am looking forward to seeing the finished product.

[MissionMan]

Wouldn't a 3D printer work a lot better for these kinds of parts?

[AsignObservatory]

More performance art than photography, but fascinating. Keep it up.

Some of the past photos are done with the DSLR, lighting etc and it was good practice for product-type photography. Problem now is the only camera I have is the family cheap DSLR which I don't really want to have in the shed with all the metal filings etc., My phone camera (rubbish) is doing all the documentation for now. I'll bring the DSLR out for some of the bigger, better progress reports.


Love these progress reports. Are you going to get tired of all the filing you are going to have to do to complete this? I hope not as I am looking forward to seeing the finished product.

Filing is one of those things that many people hate, like running. The thing is, it's one of the most accurate ways to get it right instead of rushing it with a grinder or something more aggressive.


Wouldn't a 3D printer work a lot better for these kinds of parts?

That's a bit like saying, "Rocket to the moon? Wouldn't teleportation be better for that kind of travel?" :p

There are people out there doing similar things with 3D printers, and they are welcome to it. My intent is to create something beautiful, functional and impacting with a small selection of common hand and power tools. Not everyone can afford a 3D printer, much less operate one and all the design software required.

Plus, 3D printers aren't yet printing in metal as far as I'm aware.

Chalk and cheese mate.

[Steve Axford]

I think the photography here is one of the means of cataloguing the journey, and it is the journey that is the important thing. Then there's the story of what you do with it when it's built and that will be even more performance art - but I hope we get a photo record of that too.

[MissionMan]

Some of the past photos are done with the DSLR, lighting etc and it was good practice for product-type photography. Problem now is the only camera I have is the family cheap DSLR which I don't really want to have in the shed with all the metal filings etc., My phone camera (rubbish) is doing all the documentation for now. I'll bring the DSLR out for some of the bigger, better progress reports.



Filing is one of those things that many people hate, like running. The thing is, it's one of the most accurate ways to get it right instead of rushing it with a grinder or something more aggressive.



That's a bit like saying, "Rocket to the moon? Wouldn't teleportation be better for that kind of travel?" :p

There are people out there doing similar things with 3D printers, and they are welcome to it. My intent is to create something beautiful, functional and impacting with a small selection of common hand and power tools. Not everyone can afford a 3D printer, much less operate one and all the design software required.

Plus, 3D printers aren't yet printing in metal as far as I'm aware.

Chalk and cheese mate.

Apologies, I meant no offence. I meant mainly for the prototype processes in the sense that it may be easier to scale parts larger and smaller and once you have it perfect you can convert it. Some of the larger 3D printers are now in the sub $1000 territory.

You then also have the capacity to sell the final design and make back some of the time you've invested in it

[rellik666]

Amazing.......

Love it. Can't wait to see the finished article.

Just FYI, you can 3d print metal and the aerospace industry (to name one) is doing it. But yes not available for the home hobbyist! LOL!

[AsignObservatory]

I think the photography here is one of the means of cataloguing the journey, and it is the journey that is the important thing. Then there's the story of what you do with it when it's built and that will be even more performance art - but I hope we get a photo record of that too.

You can be sure I'll do my best to photo-document it all the way. Hopefully I'll start to get all my pro gear back again and do some creative photography with the suit. The imagination is running wild already!


Apologies, I meant no offence. I meant mainly for the prototype processes in the sense that it may be easier to scale parts larger and smaller and once you have it perfect you can convert it. Some of the larger 3D printers are now in the sub $1000 territory.

You then also have the capacity to sell the final design and make back some of the time you've invested in it

Absolutely no offence taken at all dude. I'm just explaining it a little better in context of what I hope to do with it and how I intend to get there. You are right, a 3D printer would be handy - very handy, but I think I am really enjoying doing it the hard way. A 3D printer would take a lot away from this adventure I think. A mate of mine has just bought a 3D printer. We are unboxing it this week.


Amazing.......

Love it. Can't wait to see the finished article.

Just FYI, you can 3d print metal and the aerospace industry (to name one) is doing it. But yes not available for the home hobbyist! LOL!

Really??!! That IS interesting!

[AsignObservatory]

Got about an hour and a half this afternoon to work on the aluminium suit.

http://i.imgur.com/tdqeiP7.jpg

http://i.imgur.com/yUMMPtY.jpg

[AsignObservatory]

Abs, ribs, lumbar and spine templates ready to trace onto aluminium.

http://i.imgur.com/kttmfUR.jpg

Templates traced out onto 3mm aluminium.

http://i.imgur.com/tkU71wJ.jpg

Spine done in aluminium and pre-polished.

http://i.imgur.com/0qodK32.jpg

[AsignObservatory]

1. Abs sections cut from 3mm aluminium.

http://i.imgur.com/gnMyoPr.jpg

2. Shaping one of the overlapping aluminium plates at the back of the helmet around to the ears.

http://i.imgur.com/fkmoczc.jpg

3. Earpiece showing folded tabs to be ground and sanded smooth. I found that if I tried to simply bend the tabs to 90 degrees, they would invariably fatigue and crack or even snap off. Fix? Clamp it between two pieces of thick steel and beat it over with a hammer and flat punch.

http://i.imgur.com/vkGWQDr.jpg

4. Got a bit of work done today.

http://i.imgur.com/h0ffttg.jpg

[agb]

That is coming along very well.

[AsignObservatory]

Iron Man suit slowly progressing. Managed to get all the old paint off this second-hand aluminium. This is the armour at the lower back and around waist to meet up with the abdominal plates.

http://i.imgur.com/EL9KlHX.jpg

[AsignObservatory]

The joys of second-hand donated aluminium...

Managed to get all the old powder-coating off the aluminium abdominal armour plates today. Next - a quick polish and start shaping and joining.

http://i.imgur.com/4zyJAJB.jpg

[AsignObservatory]

So, as no one has a TIG welder I can use to weld aluminium, I have decided to change materials AGAIN, to steel. I have access to a MIG welder plus I can MIG weld pretty well.

Before I go cutting shapes and building a faceplate again, here is a trial cut and weld of an old steel plate. First, clean it up then cut a small test piece, then beat a bit of a curve in it, then cut a 1mm slot in it, then weld the slot up, then grind it smooth again.

http://i.imgur.com/hd8pjRX.jpg

Test sample steel plate.

http://i.imgur.com/boYpgY2.jpg

Beaten into a bit of a curve then a 1mm cut in it.

http://i.imgur.com/GQR1sTK.jpg

1mm cut welded up and ground smooth. This all took nearly five minutes.

http://i.imgur.com/5ivUCdt.jpg

[agb]

Does that mean starting from scratch with the metal version? Seems a shame and the new version will be heavier won't it

[AsignObservatory]

How many did Tony Stark make!? :P

That's why we prototype. Each time we find a better or more efficient way of making it. The cardboard complete suit showed me that it is possible. The aluminium would be perfect except that a TIG welder is beyond my financial reach and I would need lots of practice to learn the TIG welding technique.

Steel and a MIG solves both problems. A little heavier? Sure, but still can do.

[AsignObservatory]

Might be able to keep going with the aluminium build after all!

A very generous and total stranger has just offered his TIG welder to me to construct my Iron Man suit!

[AsignObservatory]

Thanks so much to my new random internet friend named Ben for dropping off his TIG today! You are so very kind and generous to give so freely mate! Now I can really get going on the suit!

These kids in their wards are going to go beserk with happiness! :D

Baz.

http://i.imgur.com/KdWuAfU.jpg

[Dug]

That TIG unit looks the business also.
Did it come with a few pointers and the setting adjusted to the job at hand?

Aluminum is going to be a lot nicer to work with and wear than steel.

You are going to come away from this with a nice skill set.

[AsignObservatory]

That TIG unit looks the business also.
Did it come with a few pointers and the setting adjusted to the job at hand?

Aluminum is going to be a lot nicer to work with and wear than steel.

You are going to come away from this with a nice skill set.

That's what I'm hoping! :D

[CycoKilla]

This thread is just amazing!!!
WOW!

[AsignObservatory]

I had a little practice run at TIG welding tonight.

Finally, I have found something I am not only bad at... but I totally suck at beyond human comprehension.

I have absolutely no idea what I am doing at all.

This is so hard, it's almost discouraging enough for me to scrap the whole project.

http://i.imgur.com/Fzy0nRw.jpg

- - - Updated - - -

It really is frustrating when you hit a wall like this.

Trying to keep my spirits up and a positive attitude, I picked up the correct grade of aluminium today, (5005). Clean, no paint or residue and the proper one for welding and anodising.

http://i.imgur.com/K75z4qj.jpg

Got the aluminium supplier to guillotine some 1mm strips off the parent sheet so I can use the same grade as a filler rod when welding.

http://i.imgur.com/oiC4qPx.jpg

These should keep me going for a while.

http://i.imgur.com/z6MBGgR.jpg

- - - Updated - - -

NOPE NOPE NOPE NOPE NOPE!!! GAAAAAHHHHH!!! :mad:

This time I used clean sheet, no contaminants and had a practice weld. I was happy with it.

http://i.imgur.com/4HcrUab.jpg

The moment I went to a suspended gap weld, it went to shit.

http://i.imgur.com/Ls3Klyg.jpg

So I ground it back, cleaned it and had another go. Worse. :mad: :mad:

http://i.imgur.com/8QNkvPe.jpg

Stuff this. I'm about to give the whole project away.

- - - Updated - - -

Well, it's decision time. Time to close the door on the aluminium build.

Ben, who lent me the welder came to my aid today to see if I am trainable in TIG welding. I'm not.

The hardest part was accepting the fact that I am not good at something I really want to be. It actually comes as a relief. Time to move on to the things that I am good at.

TIG welding a job like this is something to be attempted by someone with years of TIG experience. Even then, it's a daunting job.

I know it is unrealistic to expect to be instantly good at it. I realise it does take a lot of time to practice, but it's time I don't have.

I'm going back to steel and going to be MIG welding, which I can do. The suit will be heavier sure, but still manageable. I can fabricate in steel in a fraction of the time it takes to do the same in aluminium.

I'd like to take this opportunity to thank Ben_Wilson publicly for his tremendous generosity and helping heart in this, as well as Mad_Mic3 for his very inforamative PM's he sent me to help, which look like he put a lot of time and effort into composing for me.

Here's 3 pics to illustrate the arrival at what I think is a sound decision to move on.

http://i.imgur.com/zVkOnWX.jpg

http://i.imgur.com/cm6TFUX.jpg

http://i.imgur.com/nLuecTi.jpg

- - - Updated - - -

Playing with cold-rolled mild steel now. Very soft and easy to work.

Finally got the metal-cutting blade for the band-saw, cut two pieces out beautifully and as I switched the saw off, it went BANG! $40 Brand new blade broken.

I'm seeing a pattern of every time a door opens, another one closes on this project. How many years have I been at this? :squint:

http://i.imgur.com/ZupWtJt.jpg

http://i.imgur.com/wGO0ewM.jpg

Getting very fast at this part. Cut and shaped it in 1/2 an hour. Ready to weld. Should be able to get this welded up on Saturday.

http://i.imgur.com/FhMzAvI.jpg

- - - Updated - - -

Had a little win last night. My aircraft-grade tin-snips cut the smaller pieces with ease. Bottom lip cut in less than two minutes.

http://i.imgur.com/PTPAxv1.jpg

SUCCESS!!!!! I welded the steel faceplate all up this afternoon! A bit of fiddling with the settings on the welder as I am not used to welding steel this thin, (1mm). Now to grind it back and sand it smooth. Let the real suit begin!!!!!!!

http://i.imgur.com/q9KH6JP.jpg

http://i.imgur.com/TGt3f7n.jpg

- - - Updated - - -

Grind back with a flap disc. Looking good.

http://i.imgur.com/nyPUags.jpg

http://i.imgur.com/zt6c7MU.jpg

- - - Updated - - -

Did some fill-welding in low points and cracks then re-ground smooth.

http://i.imgur.com/IEAbR1Y.jpg

Welded in some thin strips in the eyes. I'll be doing this right around the faceplate.

http://i.imgur.com/XC3GEsw.jpg

Thin strip filed smooth and shaped the edge. That's starting to give it some depth now.

http://i.imgur.com/qzCD9KT.jpg

Started on the next bits. Small steps and taking time will get this done.

http://i.imgur.com/u8nlCIl.jpg

- - - Updated - - -

I had a day off work today, so I spent most of it in the workshop. All the parts for the helmet cut out and beaten into shape, ready to tack together and weld.

http://i.imgur.com/GEI287K.jpg

- - - Updated - - -

A few bits and pieces cut, shaped and ready to weld.

Handplate.

http://i.imgur.com/yBMJmWX.jpg

Knuckles.

http://i.imgur.com/JMLdjI0.jpg
http://i.imgur.com/laRzSiK.jpg

Fingers.

http://i.imgur.com/kQ9oLZJ.jpg
http://i.imgur.com/YexBKxg.jpg

- - - Updated - - -

Sizing and aligning the steel parts.

http://i.imgur.com/tBtUr0s.jpg

[ameerat42]

Don't give up!!! You could do WORSE: get ME to TIG weld it. :rolleyes::eek:

[AsignObservatory]

Don't give up!!! You could do WORSE: get ME to TIG weld it. :rolleyes::eek:

I'm not giving up. I've moved to steel instead.

[AsignObservatory]

Fabrication ramping up! Hopefully I'll get the helmet all welded up tomorrow.

http://i.imgur.com/aa6FaT5.jpg

[rellik666]

Amazing.....

[AsignObservatory]

Thanks Roo. :)

I got the helmet spot-welded up today.

http://i.imgur.com/ysNhgr1.jpg

http://i.imgur.com/3BTrflM.jpg

[AsignObservatory]

More welded on today.

http://i.imgur.com/kEDgmlg.jpg

[AsignObservatory]

I only got ten minutes to work on this today. Here's a back view showing the seams all welded up, then ground back using an angle grinder and grind-wheel first, followed up with a flap disk.

http://i.imgur.com/I1Dr23P.jpg

http://i.imgur.com/ejw8Djj.jpg

[Glen1]

Mate, let me just say, I bet you have a very understanding missus. As a Fitter and Turner, I can appreciate the level of skill required to achieve your current build level. If the thing flies, i'll be really impressed.

Regards,
Glen1

[AsignObservatory]

Mate, let me just say, I bet you have a very understanding missus. As a Fitter and Turner, I can appreciate the level of skill required to achieve your current build level. If the thing flies, i'll be really impressed.

Regards,
Glen1

Cheers Glen. Understanding wife, mixed with, she's got no choice... ;)

[AsignObservatory]

Collar plate, hand plate and hip pod.

http://i.imgur.com/aDXBFtC.jpg

http://i.imgur.com/t8zA2Or.jpg

http://i.imgur.com/BEdL1ZO.jpg

[AsignObservatory]

Cleaning up the welds a bit more tonight. Getting the edges tidy on the cascading segments at the back of the helmet.

http://i.imgur.com/Cn1oAof.jpg

http://i.imgur.com/xPYVTMB.jpg

I've tried getting into these corners with a file, a flap disk, a Dremel and sandpaper. It's hard work and very slow going. Can anyone reccomend a good tool to get into this? An electric reciprocating mini-file would be awesome!

http://i.imgur.com/SfvsVa0.jpg

[AsignObservatory]

Today I got a few hours in the shed finally. I got half way through the job and broke another bloody bandsaw blade. Same as before, cutting beautifully for hours then snaps when I turn it off and it begins to slow down. This is costing me a small fortune in blades at $40 a pop!

Anyway, I grabbed my aviation snips and went manual. I'm going to get very strong hands like this.


http://i.imgur.com/q3fVyyQ.jpg

http://i.imgur.com/1feSXn4.jpg

http://i.imgur.com/q2N6KVv.jpg

http://i.imgur.com/c7oQA0m.jpg

http://i.imgur.com/l7087CC.jpg

[AsignObservatory]

I'm so confused by man. At the same time that we are chopping each other's heads off, we have a spacecraft orbiting an incoming comet, about to land on it as it awakens under the sun's increasing influence.

Pretty deep yes?

Well then, here's another. A random internet acquaintance whom I've never met and who wishes to remain anonymous, sent me advice, photographs, technical knowledge, support, encouragement and contacted me to ask if I would like him to build an arc reactor for the centre of Iron Man's chest. Based on a single measurement from me and a handful of photos, he built this in just a few days.

Not only that, he wanted no money, no return favours or even fair recompense for materials or even postage.

While there are some horrible humans out there, there truly are some wonderful ones too.

Best of all, I have the honour to have interacted with him, even if it was from afar.

http://i.imgur.com/X1kO2xL.jpg

[Debra Faulkner]

Excellent! Just goes to show there are always pleasant surprises somewhere, sometime by someone! :th3::th3::th3:

[AsignObservatory]

Time to start modifying! My mysterious benefactor has provided me with an excellent bunch of hardware to fit all my lighting and power into.

Using my drill press as a vertical lathe, I used the tip of a spade borer to part the outer ring from the rest of the perspex disk. The inner I might use later but for now it's not needed.

http://i.imgur.com/fwokPWv.jpg

Similarly, the centre of the aluminium disk underneath is not needed, as I need to allow a clear path for lighting to the front from the source in the back. For this, I just used the bench drill to stitch-drill it all out, then hand-filed it clean. I left four tabs to screw it to the bottom of the reactor. The tabs still need tidying up a little to make them neat.

http://i.imgur.com/EVIqTWu.jpg

Here's a quick pre-assembly. I need to make some more bits before the lighting and power goes in.

http://i.imgur.com/YPO9pWC.jpg

[AsignObservatory]

I got one boot all spot-welded up today. Fits good and hinges well in the middle.

http://i.imgur.com/F8bUf51.jpg

[Dug]

I've tried getting into these corners with a file, a flap disk, a Dremel and sandpaper. It's hard work and very slow going. Can anyone reccomend a good tool to get into this? An electric reciprocating mini-file would be awesome!

If you have compressed air on then a pencil grinder or small air grinder will probably be the go. Similar in operation to a Dremel but more grunt. https://www.youtube.com/watch?v=um0T189VJWo
Will also require a regulator/oiler like this https://www.youtube.com/watch?v=CGvhXJzyrE0
Weld is pretty hard so a combination of round ended grindstones and carbide burs will cut through it.
A light touch is required letting the cutter do all the work otherwise there is a tendency for the cutter to skate off the weld (due to the rotation) and take a divet out of the material to the side of the weld.

Practiced welders can lay fine even welds that don't bulge up, its all in the settings and watching what the puddle is doing. Such a weld could be just covered with a fillet of body filler I imagine in a lot of cases where edge definition if not essential, saving a lot of work.

[AsignObservatory]

If you have compressed air on then a pencil grinder or small air grinder will probably be the go. Similar in operation to a Dremel but more grunt. https://www.youtube.com/watch?v=um0T189VJWo
Will also require a regulator/oiler like this https://www.youtube.com/watch?v=CGvhXJzyrE0
Weld is pretty hard so a combination of round ended grindstones and carbide burs will cut through it.
A light touch is required letting the cutter do all the work otherwise there is a tendency for the cutter to skate off the weld (due to the rotation) and take a divet out of the material to the side of the weld.

Practiced welders can lay fine even welds that don't bulge up, its all in the settings and watching what the puddle is doing. Such a weld could be just covered with a fillet of body filler I imagine in a lot of cases where edge definition if not essential, saving a lot of work.

Thanks Dug. I'm looking at a die-grinder at super-cheap auto.

- - - Updated - - -

My very skilled uncle turned some brass rings to my specs. I got a little time to assemble them today.

http://i.imgur.com/npggM03.jpg

Brass rings assembled and fitted into the reactor.

http://i.imgur.com/MrWUjAs.jpg

[AsignObservatory]

Today I cut the guts out of the front plate and fabricated my own from a piece of pipe and some flat steel strips welded and bent.

http://i.imgur.com/iQUn3Gv.jpg

Tonight, drawing up a paper template to mark holes to be drilled around the circumference of the front ring. The movie accurate one has elongated slots, but I only have a drill, not a mill so my holes will simply be round.

http://i.imgur.com/WWAF7aU.jpg

[AsignObservatory]

Arc reactor front ring punched and ready for drilling. Sometimes I wish I had some decent machinery to do all this, but it's kind of cool to see how well I can do with hand tools and hand-held power tools.

http://i.imgur.com/Q9NNXaO.jpg

Holes drilled. A bit of polishing and some socket heads and it's ready to go on the front of the reactor.

http://i.imgur.com/B7rmRqv.jpg

Trying to remain constructive at work after everyone else has gone home. Lots of waiting for the public to leave the park before locking up. Sure beats wasting time watching the idiot box. Got another hand plate, the second boot and part of a collar plate cut out. Using aviation snips buckles the sheet steel no end, but I'll planish it back out on the anvil.

http://i.imgur.com/H1YXdno.jpg

Assembly nearly complete. Still to go: drill out the bottom of the reactor and install power and lighting. I think I'm going to re-do the little square transformers around the outside before I wrap them in copper wire.

http://i.imgur.com/M3OtGyR.jpg

[AsignObservatory]

Making progress on the second boot.

http://i.imgur.com/4TJ6mrz.jpg

Cut the bottom out of the body to allow for the bight and power going in later, then lined the inside of the reactor with a metal tape specially designed to reflect spectrum in laboratories. Good to know people in the game. You can see already what the tape is doing to the sunlight hitting it. Once I have lighting in there, it should bounce around like a bastard.

http://i.imgur.com/lA61izn.jpg

Making the little transformers for the particle accelerator on the front of the arc reactor.

http://i.imgur.com/CfY8ehI.jpg

Starting to fit transformers on the reactor.

http://i.imgur.com/WmXgOu8.jpg

[Nick Cliff]

Am enjoying your journey, a renaissance Iron Man Baz to be sure, are you planning on visiting the Glenrowan Hotel incognito,
Regards Nick.

[AsignObservatory]

Am enjoying your journey, a renaissance Iron Man Baz to be sure, are you planning on visiting the Glenrowan Hotel incognito,
Regards Nick.

All I need is an invitation mate. :D

Assembling the parts for the particle accelerator on the front of the reactor.

http://i.imgur.com/5RE8bVR.jpg

Assembly complete and ready for lighting.

http://i.imgur.com/yRTwsPd.jpg

What do you think of THIS for a nuclear power source? :P

http://i.imgur.com/qBRingR.jpg

[AsignObservatory]

The collection grows! Very soon some of it will be wearable!

Apparently as I can't get any palladium or unobtanium, I have to come up with my own new element to power my Arc Reactor. Bazidium is currently being looked into....

http://i.imgur.com/VrqySre.jpg

[Dug]

Your reactor reminded me of reading this:
http://sploid.gizmodo.com/lockheed-martins-new-fusion-reactor-might-change-humani-1646578094
A semi trailer size fusion reactor in 5 yrs.
So give it ten, twenty yrs and you might be able to get something at Battery World the size you want :)

[AsignObservatory]

Your reactor reminded me of reading this:
http://sploid.gizmodo.com/lockheed-martins-new-fusion-reactor-might-change-humani-1646578094
A semi trailer size fusion reactor in 5 yrs.
So give it ten, twenty yrs and you might be able to get something at Battery World the size you want :)

Maybe I'll beat them to it.... :P

- - - Updated - - -

Today I worked on the abdominal armour. This is the aluminium I cut a while ago, not steel. I thought I'd at least try to put it together and shape it. If it works, I may be able to use it. If it looks too ugly, then it will be a good first run before I go to steel.

http://i.imgur.com/y0EazVf.jpg

http://i.imgur.com/AOnqUXo.jpg

http://i.imgur.com/CAgURtx.jpg

[Glen1]

I dunno about that Unobtainium stuff, but I'd definitely steer clear of baked beans or curried eggs when you're planning to wear that suit. Might pay to build a vent in, round the back.

Regards
Glen1

[AsignObservatory]

Onya Glen.... :P

Arc reactor powered up.

http://i.imgur.com/7tCvJ2n.jpg

[Andrew B]

nice work

[AsignObservatory]

Ta mate.

Here's the latest on the suit.

http://i.imgur.com/bWco3L8.jpg

[AsignObservatory]

http://i.imgur.com/ijY3Pjv.jpg

[AsignObservatory]

Started out feeling a little flimsy, but it's pretty solid now. Lots of clean-up to do next.

http://i.imgur.com/yG84MHw.jpg

http://i.imgur.com/g1zeacg.jpg?1

http://i.imgur.com/yMlT4aT.jpg

[AsignObservatory]

Torso coming together.

http://i.imgur.com/f4sDFmk.jpg

I put the hand together just for fun, but I am not going to use it. I don't like it, don't like the way it moves, (or doesn't), so I will probably make it out of stained thick cow-hide.

http://i.imgur.com/NSVWZsd.jpg

[AsignObservatory]

Mammoth day today. Went for a drive to pick up some more cold-rolled mild steel sheet, scrounged the local salvage yard and finally found what I was looking for - an old overhead projector. Picked it up for ten bucks. All I want is the lenses.

Once home, I traced out all the parts for the cod-piece and chest/back brace, got a lot of blisters from the aviation snips and a tennis ball sized muscle in my forearm.

I then hacked up the OHP for a s####y new cover on the arc reactor.

http://i.imgur.com/x7SN2xU.jpg

http://i.imgur.com/kZnYP0K.jpg

http://i.imgur.com/hbl64fO.jpg

http://i.imgur.com/0bor8HM.jpg

http://i.imgur.com/yEddQZ9.jpg

http://i.imgur.com/00FBCzG.jpg

http://i.imgur.com/uIvOmSr.jpg

[AsignObservatory]

Here's all the bending and folding I got done tonight with a couple of pairs of pliers, gloved hands and the occasional tap with a mallet. So hard to do this quietly at night!

http://i.imgur.com/p9UlXeO.jpg

[AsignObservatory]

Finally the young bloke is old enough to start learning a trade. Helping dad flatten out some temporary joining plates for the iron man suit and then loading the rivet gun with, "very special green rivets".

http://i.imgur.com/hqMk8Ra.jpg

Bending and folding the chest brace to mirror the cardboard prototype. Pop-rivets just holding shape until i weld it up.

http://i.imgur.com/1oCtwn3.jpg

[AsignObservatory]

Chest brace welded up for the most part. I won't be cleaning it up until I get the back done and fitted.

http://i.imgur.com/oB08uDv.jpg

Chest piece loosely fitted over the chest brace with the two collar plates.

http://i.imgur.com/S1n936t.jpg

[AsignObservatory]

A couple of productive hours after work today. I tack-welded the cod-piece and neck seal together. I have a lot of beating and shaping on some home made dollys to get it all fitting together perfectly, then I'll weld it all up and grind it back neat.

I pre-assembled the main torso parts together to have a look at it all for fit. The old attempt at the abdominal armour in aluminium is going to be scrapped in favour of a more workable and bendable steel one. I'll get on to that this week hopefully.

http://i.imgur.com/O14xqjk.jpg

http://i.imgur.com/cENEMNh.jpg

http://i.imgur.com/uDm5VF9.jpg

[agb]

I'm still amazed at this and love looking at it.

[ausfitter]

Mate this is coming along nicely.. Looking forward to seeing the finished product...

[AsignObservatory]

Here's today's work. One shoulder bell with the cardboard trial beside it for comparison.

http://i.imgur.com/XLpxiEA.jpg

http://i.imgur.com/RF11731.jpg

[Allie]

Pretty neat, Barry - very much like the finished product :th3:

[AsignObservatory]

Pretty neat, Barry - very much like the finished product :th3:

Oooooh it's a long way from finished product yet Allie! :D That's just rough chassis for now.

- - - Updated - - -

GAHHH!! I must be exhausted. I spent most of the day in the hot sun on a cabless tractor.

I think it effected my concentration....

This afternoon I got all the way through the second shoulder bell only to realise at the end that I have made half of it the same as the opposite shoulder bell.... got to cut, bend, fold and weld another one all over again! What a waste..

There's the bit at the back that should have been made the other way around.....

http://i.imgur.com/ViuMqh1.jpg

http://i.imgur.com/ZCuW1Oi.jpg

[AsignObservatory]

Re-cut and re-made the second shoulder bell today.

http://i.imgur.com/2e3byvF.jpg

http://i.imgur.com/LLOUxYt.jpg

http://i.imgur.com/RtOD3cy.jpg

[Allie]

Looks great - hope it's got air conditioning too!:D

[AsignObservatory]

Looks great - hope it's got air conditioning too!:D

I'm installing cooling fans. :th3:


I thought I'd pull a bit of a marathon tonight so I stayed in the workshop until 11pm, welding.

Back armour all assembled and welded up.

http://i.imgur.com/j9OYzNZ.jpg

http://i.imgur.com/EhDuGyS.jpg

[AsignObservatory]

I got a tweet from a TV crew today followed by a phone call and they are coming out tomorrow to do a story on the Iron Man suit for television.

I quickly had to put humpty together again as I've had him apart to model parts for the steel build.

http://i.imgur.com/evFNrbd.jpg

Now the workshop is all cleaned up, I got both shins cut out. Now to flatten, fold and weld.

http://i.imgur.com/3o0heRe.jpg

All the large parts are done on big sheets, but the little stuff can be traced onto the scraps.

http://i.imgur.com/vx7ZKSA.jpg

All the parts so far.

http://i.imgur.com/7b3vM42.jpg

[ameerat42]

E-gratulations. What program crew?

[AsignObservatory]

Another day of TV cameras here, job done! Story mainly on the Iron Man suit, but a little on the observatory as well.

It will go to air next Fri at 7:30 on ABC1, then News24 over the weekend. Online from 8pm Friday.

For those of my overseas supporters, I will be receiving a clean copy for me to upload to You tube. You'll have to be a little more patient until I receive it and upload it.

[AsignObservatory]

This tool is called a brake. It is one of the tools some lovely person on the internet donated and sent me in the mail. It makes folding neat and straight lines so easy!

http://i.imgur.com/W0oLF1H.jpg

Tonight's work. Unfortunately I have run out of steel to do any more and I won't have access to a welder for some time so works will pause until that is remedied.

http://i.imgur.com/EhXLsgQ.jpg

[AsignObservatory]

I LOVE DIE-GRINDERS!

Thanks to the guys who sent me the carbide bits and the grinder itself I got the centre of the chest armour shaped very quickly to fit the cover glass and housing for the arc reactor.

Four tabs to be welded on the ends to retain the glass housing.
http://i.imgur.com/MpoEBM2.jpg

http://i.imgur.com/yaBEkFc.jpg

http://i.imgur.com/H7NlOqK.jpg

[AsignObservatory]

Crikey I need that gas MIG! Parts are mounting up on the bench and I have no way of joining it all up without one!

Hopefully I'll be back to work next week and get a chance on the welder after hours. Contract ends soon so I may not have the job much longer and I don't know how much time I have access to it.

http://i.imgur.com/TlmvZJ2.jpg

http://i.imgur.com/Mvo3xA6.jpg

http://i.imgur.com/8qgCsd2.jpg

[AsignObservatory]

Tonight I got some of the thigh cut out properly and bent/folded into shape, ready for welding. I had to stop because the neighbors probably wouldn't appreciate me thumping away with the hammers past 9pm....

http://i.imgur.com/GUhmunq.jpg

Good fit for my long legs.

http://i.imgur.com/KNPfhBs.jpg

[AsignObservatory]

Here it is folks! My Iron Man suit on TV on ABC One's 7:30 ACT report.

I did mention quite a few people, including the guys who wrote the pepakura files, modified them, folks who donated stuff etc.

I was interviewed, filmed and photographed for a couple of hours and gave credit to a lot of people, even going so far as to say I thought it was important that they were mentioned. However, the first edit was 8 minutes and had to be cut down to 4 minutes. They did a fantastic job but only so much can be kept off the cutting room floor.

Thanks so much to all involved in helping me get this done! I can't wait to get this into a kids hospital ward!

God bless ya all!

http://mobile.abc.net.au/news/2014-11-28/iron-man-in-canberra/5927124

[nimrodisease]

Great video Barry! It's great to see the gradual process.

[AsignObservatory]

Thanks John. :)

[Duane Pipe]

Thanks for sharing the Video.
I like your skills using primitive hand tools Barry.

Iron-Man V Astro Boy.

Soon Coming to a Theater near You!

[ameerat42]

:th3: Bazza.

[AsignObservatory]

Cheers gang. :D

Today is my last day of a two and a half week break. I've had no access to a welder so I've been madly cutting and bending more parts ready for welding.

Today all I could do was grab the die-grinder and angle grinder and get some clean-up done on the existing welding.

Hopefully tomorrow after work I can get a bit more welding in.

http://i.imgur.com/AmrBA9d.jpg

http://i.imgur.com/AtNsupi.jpg

http://i.imgur.com/JwXjx0f.jpg

[AsignObservatory]

Got a lot of one leg welded up today after work.

http://i.imgur.com/dE9BsfR.jpg

http://i.imgur.com/ph0vE23.jpg

[AsignObservatory]

Got most of the first leg done this arvo after work.

http://i.imgur.com/3x1vWck.jpg

http://i.imgur.com/yqqC597.jpg

http://i.imgur.com/ys4ej5j.jpg

[Allie]

Great video Baz and a very noble cause ... it is amazing how when we lose inspiration or interest it can be renewed from an unexpected source!

[agb]

Great video Barry. Worthwhile project. Not long to go now.

[AsignObservatory]

^^^ Thanks dudes! :D



This only took about 1/2 hour to bend, align and weld up.

Short time to work with today.

http://i.imgur.com/Co6sflz.jpg

http://i.imgur.com/XRwDSD0.jpg

[CarlR]

i continue to be amazed by your effort on this, Barry.

[J.davis]

Its good to see how your skills are improving as the build progresses. Like watching an apprentice advance through a trade.
Have you given a thought as to how much this suit will weigh on your outings. :D

[AsignObservatory]

i continue to be amazed by your effort on this, Barry.

Thanks for jumping on the wagon with me! :D Enjoy the ride man!


Its good to see how your skills are improving as the build progresses. Like watching an apprentice advance through a trade.
Have you given a thought as to how much this suit will weigh on your outings. :D

Thanks mate.

It's a question I get asked every other day. Short answer, about 35kg.

[AsignObservatory]

One of the difficult challenges of an anatomically incorrect superhero with impossible proportions is making the suit fit without having to change the whole thing. When you scale this suit in the program that prints it, if you change the scale you change the whole thing! If I scaled up to widen at the waist, I could fit two of my bums in the rest.

My simple fix - only adjust it where you need to, AFTER scaling. My cardboard suit is perfect for making such adjustments. Cut it open, add thin strips where needed and problem solved!

Now all I have to do is the same on my steel suit. Only ten minutes work in it too! Bonus!

http://i.imgur.com/WJCAy1F.jpg

http://i.imgur.com/sSIVHE6.jpg

http://i.imgur.com/P5Vozau.jpg

[AsignObservatory]

Tonight I tried to experiment with a bit of a hybrid idea for the gauntlets. Not sure if I will go for all foam then dip in red plasti-dip, or use the metal fingers I've already made.

http://i.imgur.com/1kUsJqi.jpg

http://i.imgur.com/nxtbsdS.jpg

http://i.imgur.com/S0B6rNR.jpg

http://i.imgur.com/OH0GUfQ.jpg

http://i.imgur.com/WqTMLGQ.jpg

[AsignObservatory]

First four attachment-points in the suit's bolt-together system. I've welded in a short extension on each side then welded two sets of tabs on each side. That way the back piece slips in between two layers of steel and bolts into place. The flat nut on the inside is welded into place then ground smooth. There's a little bit of room in there for some lining yet.

http://i.imgur.com/PdnkdFv.jpg

Abdominal armour fits. Now to widen codpiece to match.

http://i.imgur.com/xYmrSFw.jpg

[AsignObservatory]

Added in the extensions for the codpiece and welded it to the abs. Next is to cut the cod in half and add attachment points like I did with the abs.

http://i.imgur.com/7v2qYCP.jpg

[rellik666]

WoW! Is it heavy to wear?

[AsignObservatory]

http://i.imgur.com/e2s8M19.jpg

http://i.imgur.com/YVizt3A.jpg

[AsignObservatory]

The hands really are the hardest part. The more rigid you make them, the harder they are to get on and off and the less range of motion you can have in them.

This is the sixth gauntlet I have made and I'm really getting sick of it. At least they are getting neater with practice.

This time I used 3mm closed-cell foam sheet. It's not finished, but once I've worked it all out I will be dipping the whole thing in plasti-dip, which will seal and lock it all together.

http://i.imgur.com/rXidWAX.jpg

http://i.imgur.com/NKuOzgx.jpg

[AsignObservatory]

http://i.imgur.com/84k4qDn.jpg

http://i.imgur.com/IvduVUR.jpg

[JJM]

That looks unreal Baz, keep up the great work!!!

[AsignObservatory]

That looks unreal Baz, keep up the great work!!!

Cheers mate!


Today I cut out all the parts for Iron Man's biceps ready for folding and welding.

I've also cut and flattened all the parts for the remaining thigh, (not pictured).

My hands are covered in blisters from the aviation snips so I'll have to give cutting a rest for a couple of days while they heal.

http://i.imgur.com/HiFj3Zc.jpg

Also got everything done on both gauntlets including a PVC ring glued in and ground down to just proud of the palm surface. These will be fitted over cotton gloves then the whole shebang painted with a thin layer of plastidip to seal it, followed by a nice thick dunk in the stuff to lock it all in together.

http://i.imgur.com/8DR5DHm.jpg

[AsignObservatory]

Bicep parts shaped ready to weld.

http://i.imgur.com/ezQBG6n.jpg

[AsignObservatory]

Today I got the remaining thigh done.

http://i.imgur.com/lu6ik7A.jpg

http://i.imgur.com/9Dt2Bn0.jpg

http://i.imgur.com/ljUG4Iz.jpg

http://i.imgur.com/xT2VYzm.jpg

[AsignObservatory]

First bicep welded up today and the other started.

http://i.imgur.com/I165qPf.jpg

http://i.imgur.com/4aofnDH.jpg

[AsignObservatory]

The final pieces cut out for the Iron Man suit. Forearm and elbow armour.

Once these are done, it's time to start modifying it all to wear!

http://i.imgur.com/wbwg5t8.jpg

[AsignObservatory]

Forearm done today. One to go.

http://i.imgur.com/hZsSVQA.jpg

[Duane Pipe]

Its coming along nicely Barry, I like you skills. My concern is cracks forming once you have ground the But-Welds smooth.

[AsignObservatory]

Its coming along nicely Barry, I like you skills. My concern is cracks forming once you have ground the But-Welds smooth.

Don't be concerned mate. I'm not. They are sure to be there. When I find them I'll fill them in. Not a drama at all.



Both arms done. That's all the main parts of the suit fabricated. Now to start refining it part by part.

http://i.imgur.com/0HyKPgo.jpg

[AsignObservatory]

Here you go. Time to go on a bit of a Christmas break for a few days. I think I've earned it.

http://i.imgur.com/Z1bwwmv.jpg

[AsignObservatory]

Merry Christmas gang!



I've been working in secret on a gift for my wife for Christmas. I saw the idea online somewhere and embellished on it a little.

The mini-arc-reactor pendant is just the rearranged parts of an internal hard drive motor. I bought a single LED, some thin insulated wire and a 3V battery, along with some beads in Iron Man colours from the local 2Dollar store.

The battery has a soft cover to hide behind her hair, but not pictured here.

http://i.imgur.com/a4XxptJ.jpg

http://i.imgur.com/L2qVU2U.jpg

[AsignObservatory]

Most important and got it right this time! I can bend my arm enough to replenish fluids by myself during the long gigs in a steel suit! Rock on!

http://i.imgur.com/rYMR9Hl.jpg

Legs are a fantastic fit. I can bend to 90 degrees, there's room for padding too. I have to pull them up slightly to get them off the ankles and up into the crutch more, so some nylon straps will fix them to the hip pods to sort that out.

http://i.imgur.com/nmv2s6A.jpg

http://i.imgur.com/gfVQBIP.jpg

[keith-killer]

This is very cool! You are certainly very skilled.

[AsignObservatory]

This is very cool! You are certainly very skilled.

Thank you sir! I'm still learning.... :)


Fabricated the ear covers today and welded them in. It's snug. Just enough room on the sides for a soft-lining.

http://i.imgur.com/qe0Kxh0.jpg

http://i.imgur.com/oTsk6Py.jpg

[Duane Pipe]

It must have hurt drilling holes through your knees, Ouch..

[AsignObservatory]

It must have hurt drilling holes through your knees, Ouch..

Knees mend. :P I had someone screwing bolts into my neck today with a cordless drill. :D


Neck/collar now has break-apart attachment points to fit me. Ready to sand, paint and fit soft lining inside.

http://i.imgur.com/BerxJ8b.jpg

[AsignObservatory]

I started mods to the helmet today. I separated the faceplate by cracking the spot welds with a fine and sharp cold-chisel on the anvil.

I welded in some edging to make the helmet look like it's made of heavier material. Most of this I did before separating the faceplate to minimise distortion due to welding heat. Some of it I had to do after because there simply wasn't enough room to get the welding gun in there.

Added the last section at the back of the helmet that swings up to allow the head in then locks behind the back of the neck.

http://i.imgur.com/grtVP1F.jpg

http://i.imgur.com/9Wyea2A.jpg

http://i.imgur.com/3psRqbU.jpg

http://i.imgur.com/rmHzxWl.jpg

[AsignObservatory]

Plenty of room. Once the padding goes in it will sit up higher on my head, bringing the chin in line with mine.

http://i.imgur.com/9EVuV5V.jpg

Room in the chin for electronics.

http://i.imgur.com/6tMKU1I.jpg

Snug fit. No bobble-heads.

http://i.imgur.com/zffpxBw.jpg

All the edging welded in now. Just a bit more clean-up to get all the seams to match up again. This view shows the bottom section closed behind the back of the head.

http://i.imgur.com/6EmPMhk.jpg

[ameerat42]

Hmm! Iron Man doubts: a toss-up between R Downey Jr and David Wenham.:cool:

[AsignObservatory]

Hmm! Iron Man doubts: a toss-up between R Downey Jr and David Wenham.:cool:

^^ Onya. :P


What I love about this build is that I am learning so many skills outside of what I already know. I'm about to learn a whole lot about amps, volts, ohms and all that stuff. The electronics to go in this suit even have some programming and circuit-boards for command and control to be installed and configured for tasks. I have no idea yet but I guess I'll be learning.

I made a start with lighting today. It's all about improvisation, adaptation and overcoming.

1. Working out the lining for the faceplate. Still some metal edges to shape neat and straight before glueing it in.

http://i.imgur.com/gOZTjls.jpg

2. Set up for a day on the kitchen bench in air-conditioned comfort.

http://i.imgur.com/fwao42j.jpg

3. Found the most awesome and excellent solid strip lighting that once removed from the housing, is the perfect size for the eyes of the Iron Man face-plate. MEGA bright!

http://i.imgur.com/HyGN4xg.jpg

4. LED strip-lighting to go on the inside rim of the Arc reactor. The new soldering station my lovely wife got me for Christmas is an instant hit! The old Bunnings soldering iron was more like a low-heat wood-burning tool, more frustrating than trying to pick a hair off a flea with a boxing glove.

http://i.imgur.com/Wye4QVC.jpg

5. I have a power pack of ten 1.5V AA batteries to power the short strip of 12v LEDs.
Although the strip lighting has resistors in between each set of 3 LEDs.
I ran it for a few seconds and found it getting warm. After a couple of minutes it was getting hot.

My stupid memory was jogged by a good man that the current was too much, here's how I fixed it.

AA recharegeable batteries are 1.2 volt each. Off-the shelf batteries are 1.5 Volt, so ten of them gives me too much at 15 volts. (Only need 12 volts.) I've soldered in an extra wire that effectively cuts out two batteries when I am using the higher voltage ones. When I use recharegeables I just use the black wire instead of the grey one to hook up the negative.
I've had it running for ten minutes now and while it is still warm to the touch, it's not hot anymore.

http://i.imgur.com/HDt9FKN.jpg

6. Now I've finally got the lighting sorted out in the arc reactor with a big improvement. The cabinet light in the bottom looked great, but even with the laboratory-grade reflective tape lining the inside, the outer opaque ring was not catching the light and illuminating enough. With the LED strip light installed just inside the top, problem solved and looks awesome.

Kitchen lights were on for this photo and is unedited.

http://i.imgur.com/UEXJJgV.jpg

[AsignObservatory]

Had fun today pulling apart some lovely little bright LED torches and resoldering longer wires on the COB to get the illuminated strip out of the main body.

Now I have two strips just the right size for the eyes and two neat little battery tubes to install in the suit for easy battery changes.

http://i.imgur.com/oBWmJLu.jpg

http://i.imgur.com/xLuVgeN.jpg

http://i.imgur.com/vzo9mFY.jpg

[AsignObservatory]

This is the line that the edges need cutting back to. Just wide enough to house the lining, allowing a millimetre of lining to sit proud of the edge.

http://i.imgur.com/gAhyHPo.jpg

[AsignObservatory]

All the edges ground down.

http://i.imgur.com/a9XCuAS.jpg

http://i.imgur.com/KtfywHm.jpg

And a bit of a polish for motivation's sake.

http://i.imgur.com/RPNBGv9.jpg

[AsignObservatory]

1. Each time I'm asked if I'm going to make it fly.... :P

http://i.imgur.com/7oIVb4R.jpg

2. Fitting out the soft lining

http://i.imgur.com/SNAOzeQ.jpg

3. I'm playing around with an alternative to just leaving slots above the eyes. In order to COMPLETELY fill the eyes with illumination, I must find another way to bring the outside view in. I thought of using a couple of old phone LCD screens with the phone camera lenses poking out of some convenient spots, but the problem is focusing on screens so close to your eyes. I fear it would probably do damage fairly quickly.

So, I thought perhaps playing around with mirrors to periscope it up from the gap in the mouth.

First, I practiced on some ordinary glass. (Top of image.)

http://i.imgur.com/bk0yWaQ.jpg

4. Next, I cut some small mirrors.

http://i.imgur.com/ewnIgWS.jpg

5 & 6. I glued them onto some rods so I could adjust the angles inside.

http://i.imgur.com/tDIWiXE.jpg

http://i.imgur.com/oieUzdV.jpg

I had to get someone else to wear it so I could photograph the eye through the mouth.

http://i.imgur.com/dYmXdAU.jpg

So, it works. I can see unimpeded in front of me clear as a bell. All I have to do now is refine it.

[AsignObservatory]

This evening's work.

1. Making the hinges for the helmet face plate.Aluminium struts with steel pivots to weld inside the helmet.

http://i.imgur.com/gc57xO8.jpg

2. Hinge pivot gets welded into the end of the slot so the strut can swing up out of the helmet. Other end gets welded into the inside of the faceplate.

http://i.imgur.com/6SZYQfb.jpg

3. Hinges and struts welded in.

http://i.imgur.com/NC6SG9i.jpg

4. View showing the inside where the top hinge swing-arms (struts) are welded in.

http://i.imgur.com/ofshOx2.jpg

5. Top two swing-arms done. Two to do on the bottom - offset parallelogram style.

http://i.imgur.com/xSXVxrK.jpg

[AsignObservatory]

Did a bit of work with the boots this week. I haven't had much time.

I finished welding up all the joins and seams, added some bottom plates to glue on the tread. Cut away a part of the top so I can get my leather boots in. This piece will re-attach with some tabs and bolts later.

I cut some circles out of thick aluminium to bulk out the foot pivot. Later I have to cut some notches in them for movie-accuracy.

To raise the overall height of the suit, I will be welding in a false bottom in the heel about an inch above the bottom.

Tried them on and found them to be pretty comfortable and the foot rolls well. There's a slight pinch on the back of the Achilles tendon from the rigid steel, but I peined it out on a tow-ball so now it's got a rounded edge against the back of my foot. Little adjustments along the way and it will be fine.

http://i.imgur.com/xNC4TBi.jpg

http://i.imgur.com/9ZPPnXq.jpg

http://i.imgur.com/pEndQ97.jpg

[AsignObservatory]

Found a special brush to go on the bench grinder that removes scale and rust and leaves a brushed satin finish to the steel.

I'm ready to start installing the servos for the faceplate and then the lighting.

http://i.imgur.com/eq0tw1W.jpg

[mikew09]

The journey has been simply amazing

[AsignObservatory]

Thanks man. I am in a bit of a state of excitement and dread over starting the next project which is going to make this one look like a simple lego block.

[chubb]

This is the greatest thing i have ever seen! you are going to blow kids away with this suit!
Whats the next project???

[AsignObservatory]

This is the greatest thing i have ever seen! you are going to blow kids away with this suit!
Whats the next project???

Secret.... :P



I haven't had a lot of time on the suit lately, but I got a bit of a chance today. Next week I have some late-shift work so I should get a few hours in.

The tricky part about getting into a rigid suit, is that certain parts of your body are wider than others. I've solved this by splitting the suit in two and welding in some tabs with nuts welded on the inside.

My number two fitter will dress me with a cordless impact driver and an ice-cream container full of bolts.

I'm not going to do much clean-up until I'm sure there's no more cutting and welding mods left.

http://i.imgur.com/06gCdzd.jpg

http://i.imgur.com/OSbm8WW.jpg

http://i.imgur.com/4ia8vLB.jpg

[AsignObservatory]

When you put fat wheels on a car, often you have to roll or flare the guards. Likewise, when I try to fit my fat ass into the Iron Man suit, I have to add some extra-flared guards around the hip-pods.......


Cardboard templates to be traced onto steel.

http://i.imgur.com/pliSdE7.jpg

[ameerat42]

Now if you finish this tomorrow you can call it a Tuesday Weld. A:lol2::lol2:RRGH!!

[AsignObservatory]

Now if you finish this tomorrow you can call it a Tuesday Weld. A:lol2::lol2:RRGH!!


Over my head.... actress?

[ameerat42]

Yes (http://en.wikipedia.org/wiki/Tuesday_Weld) Baz. From the 60s I (seem to) recall.:D

[AsignObservatory]

It's been a while but I finally got some more time in the shed. This is the time-consuming part now that the suit is built, I have to cut it apart and put in joining/attachment points so I can get into the darned thing.

Also tweaked the reactor a bit and started to fit it into the chest armour.

http://i.imgur.com/Gz86X3x.jpg

http://i.imgur.com/Etycyv7.jpg

http://i.imgur.com/xNSf2HB.jpg

http://i.imgur.com/oT8AW77.jpg

http://i.imgur.com/UjTViof.jpg

http://i.imgur.com/JLYBVmS.jpg

[AsignObservatory]

Fiddly work.

Modifying the boots so they fit over my old army boots. Welded in a false heel to raise me off the ground another inch and a half then modified the top of the boot to be removable for ease of getting in and out.

Still got to trim the bolts protruding inside flush with the nut I've welded in there. Soon I can grind back all the welds, bog them up a bit smooth all the edges and paint them. Rubber soles will be glued on underneath to protect the hospital floors.

http://i.imgur.com/GqHVTFH.jpg

http://i.imgur.com/WsJCqQ2.jpg

[AsignObservatory]

30 second video of walking in the boots.

https://youtu.be/CpZXw17b3o8

- - - Updated - - -

Now that's sorted out and I can actually wear them, it's time to tweak the comfort before I clean them up and put the rubber soles under them.

I have to cut a couple of comfort lines where it pinches or rubs slightly.

http://i.imgur.com/u0C7pkw.jpg

http://i.imgur.com/gyBn3WB.jpg

Also started to build a housing inside the chest for the arc reactor.

http://i.imgur.com/eXkkeKc.jpg

[AsignObservatory]

Welded in a housing with hook tabs for elastic bands to secure the reactor. Easy removal to replace lighting should the need arise.

http://i.imgur.com/nnFD6CK.jpg

Nice balance.

http://i.imgur.com/A0At1MV.jpg

Yea boii.

http://i.imgur.com/mZDMfBQ.jpg

Balancing act.

http://i.imgur.com/mrGGLEP.jpg

http://i.imgur.com/Zfp0kwZ.jpg

[JJM]

Love checking into this thread and seeing your updates, keep up the great work Bazza :th3:

[AsignObservatory]

Love checking into this thread and seeing your updates, keep up the great work Bazza :th3:

Will do mate! :D

I've been pretty busy but got a little bit done today.

Just started installing the electronics in the helmet. As you can see it has no problems competing with daylight.

http://i.imgur.com/zQ5F13j.jpg

http://i.imgur.com/NozFAKQ.jpg

http://i.imgur.com/kM7rJgC.jpg

[AsignObservatory]

Trying to find a way to join the shoulder bell so it's not a rigid join and came up with this. Using fencing u-nails welded to the inside to make hooks, then elastic straps that will pull the armour up snug, but still allow me to lift my arm and pivot it forward and back at the shoulder.

http://i.imgur.com/6jMgAgB.jpg

Modifying elastic straps into short lengths to correctly position the shoulder bell and still allow all degrees of motion.

http://i.imgur.com/gIJMUCY.jpg

Shoulder bell now attached.

http://i.imgur.com/zgSgNIM.jpg

[AsignObservatory]

Sorry about the blurry phone pics. I got the shoulder bells and arms attached today. Now everything is on, I have to get dressed in the whole suit, go for a bit of a walk around and get an assistant to mark all the spots where I get pinches, rubs and restricted movement. Then I can trim it up.

http://i.imgur.com/q5lm3Oh.jpg

http://i.imgur.com/PUfQhUO.jpg

[kwaal]

Looking amazing!

[Euskadi67]

Sorry about the blurry phone pics. I got the shoulder bells and arms attached today. Now everything is on, I have to get dressed in the whole suit, go for a bit of a walk around and get an assistant to mark all the spots where I get pinches, rubs and restricted movement. Then I can trim it up.

http://i.imgur.com/q5lm3Oh.jpg

http://i.imgur.com/PUfQhUO.jpg

Classic! Can't wait to see it painted as well!

[AsignObservatory]

Classic! Can't wait to see it painted as well!

Me either! Thanks man. :D


Finally they meet. Brought it all home today because I have a few days at home and can get an assistant to fit it all up on me for the first time.

http://i.imgur.com/0OmZp6P.jpg

http://i.imgur.com/IIjUHr3.jpg

http://i.imgur.com/LwcW8rb.jpg

http://i.imgur.com/dRW9dvs.jpg

[mikew09]

Simply Amazing buddy

[AsignObservatory]

Thanks Mike.

Baz.

[AsignObservatory]

Thanks so much to Shane and Zoe for your assistance tonight in fitting the Iron Man suit and going for a little walk in it for the very first time complete!

Together we identified plenty of points in the suit that need modification to make movement smooth and to tie it all in together. My spring-suit underneath will be modified into an under-suit with layered foam armour to fill in the gaps. The steel neck has to be cut down a whole inch and replaced with hybrid material (foam) to allow me to turn my head. The legs need to be pulled up higher to correct location and improve knee movement.

I have to accept that there will be a fair bit of range-of-motion simply not possible, but just getting in it and moving around has made it really come alive for me!

It is way more comfortable than you would think. I was very relaxed in the suit and it is not heavy at all. I could literally spend hours in it.

Lots to go yet but tonight's full fit was a big part of making it all work!

I have a video shortly, but just waiting to see if I can rotate the stupid player footage.

http://i.imgur.com/6d68PNx.jpg

http://i.imgur.com/kqKWYkQ.jpg

http://i.imgur.com/CZ7eC8H.jpg

http://i.imgur.com/jEXCK59.jpg

http://i.imgur.com/D9jQsIy.jpg

http://i.imgur.com/NIHNgQE.jpg

[JJM]

Wohoo looking good Baz!

[AsignObservatory]

Wohoo looking good Baz!

Thanks mate.

Here's a short video of walking in the suit.


http://www.youtube.com/watch?v=rexEoxuNF6I

[AsignObservatory]

I've been so strapped for time lately. This non-daylight savings is pissing me off. Stuff-all done on the suit in a while.

Today I made a start (only had 20 minutes). Reinforced the knee pivots with some heavy pipe welded in, some M10 cuphead bolts and washers in between the layers to smooth out the pivot. They move silently now.

Hopefully tomorrow I can weld a couple of struts into each side of the boots, to push the leg up high and enable the weight of the leg to rest on the ground, rather than hang on the suit.

http://i.imgur.com/wBrHqRe.jpg

[Glen1]

No, the fitting part is all wrong. If I remember correctly, in the film, Robert Downey Jr was fitted into the suit by ROBOTS. You'd better start building those suit-bots before going too much further.

Regards
Glen1

[AsignObservatory]

No, the fitting part is all wrong. If I remember correctly, in the film, Robert Downey Jr was fitted into the suit by ROBOTS. You'd better start building those suit-bots before going too much further.

Regards
Glen1

You first.

- - - Updated - - -

Leg on the right now supported on a steel strut either side of the boot and pivoting at the ankle. The weight of the entire leg now sits on the ground instead of hanging off the suits torso. The gap between the top of the leg and the cod-piece is now a lot smaller and realistic looking.

http://i.imgur.com/i4exSLi.jpg

Won't be scratching up the hospital floors now! Glueing on rubber soles.

http://i.imgur.com/hksH1x7.jpg

[AsignObservatory]

Both legs have now been elevated and supported on pairs of solid steel struts welded to the boots and pivoting at the ankle. You can see an aluminium flat disk on the right boot - this will be replaced later with a more attractive steel turned toe-pivot. The flight control flap at the back of the ankle has been hinges so now it swings up as the boot and leg moves. The knee pivots will eventually be welded closed with an attractive cap once I'm happy I don't need to take the legs apart again. Rubber soles have been glued onto the bottom of the boots to save flooring.

http://i.imgur.com/yC0Kt8X.jpg

The rib features have now been filled in from behind with scratch-built steel caps. It looks untidy with the positioning spot welds from the front and the rest of the welding from behind, but this will all be cleaned up later.

http://i.imgur.com/1WGxVHs.jpg

The steel sheet is only .95mm thick, so to give the illusion that it is thick armoured plate I have welded in some 8mm edging all around. Welding from behind except in spots I couldn't get the welding gun into. Edges will be cleaned up last.

http://i.imgur.com/A4UEKJy.jpg

The lighting is great, but the eyes are too bright for indoors and night. They overpower the dark so much you can't see the face, so I'll be adding a resistor/dimmer so I can vary the brightness as needed.

http://i.imgur.com/kQ4pqu5.jpg

http://i.imgur.com/fFsmcTv.jpg

[AsignObservatory]

G'day my loyal minions. Here's an update for you.

My wonderful wife helped me get the legs and boots on for a test walk in the modified joints.

Now the legs are supported on steel struts welded to the boots and pivoting at the ankles. The knees have been silenced with washers in between the joints and the flight control flaps at the ankle have been hinged. They will be spring-loaded at a later date. The boots now have rubber soles to protect the floor.

Here's video and some photos.

http://i.imgur.com/gK28Djp.jpg

http://i.imgur.com/cnvZlgl.jpg

http://i.imgur.com/yTyC54e.jpg

http://i.imgur.com/ovBNxLn.jpg


http://www.youtube.com/watch?v=d_Auc3Djd1k

[chubb]

looking awesome! I love the pic of the 2 of them together.

[AsignObservatory]

So, I've designed some little steel features to add to the suit to make it look more tech and set it apart from so many other suits that leave out detail and therefore look plain. I have a machinist doing it for me because it wouldn't be appropriate for me to use the lathe at work at the moment.

This guy is way better than me anyway.

I gave him simple drawings with a few guidelines only.

He's just dropped off all bar two pieces. (I have to get him some more steel). They look brilliant. Toe pivots, knee joints, elbows, shoulders front and back.

http://i.imgur.com/8frQehw.jpg

[s1l3nt]

The amount of detail in your suits man, I dont even care what others have to say but theirs are not real iron man suits! This whole thing is way to cool haha.

[AsignObservatory]

The amount of detail in your suits man, I dont even care what others have to say but theirs are not real iron man suits! This whole thing is way to cool haha.

We'll see when it's all done mate. :D

[AsignObservatory]

I'm still hopping along on a crook foot, (nearly broke it) but I brought an office chair on wheels into the workshop after work today and got a bit of welding done around the table. One foot on the ground, the other knee on the chair. It works.

Started with an arm and shoulder, welding on the new component detailed features.

http://i.imgur.com/CLUmQMv.jpg

[AsignObservatory]

Knee pivot cap fitted.

http://i.imgur.com/qCy8uni.jpg

Foot pivot fitted. Eventually the in the middle will also disappear.

http://i.imgur.com/c4JAypJ.jpg

[AsignObservatory]

I finally started cleaning up all the welds and seams today. Most of the grunt work I'm doing with a 40 grit flap-disk. When the disk is new it can get into the long corners, but once it's worn it's just good for the raised welds.

I'll get into the hard-to-reach spots with a die-grinder.

http://i.imgur.com/NTzgGCl.jpg

[AsignObservatory]

Got a heap of grinding and clean-up done on the arms and shoulders at lunch time today. Also had a good look at articulation of the elbow and shoulder pivot point and was able to design a simple solution. More on that later.

http://i.imgur.com/ptYffuW.jpg

[AsignObservatory]

Flapdisk work on one arm all done. A bit of fine work in the corners to get to with the die grinder then it's ready to putty and paint. I've also sorted the pivoting points for a solid attachment that can be separated with effort but not come apart unintentionally.

http://i.imgur.com/TExFIB5.jpg

http://i.imgur.com/bvlwUmV.jpg

http://i.imgur.com/IkNzE7i.jpg

http://i.imgur.com/MK30lqd.jpg

[pacogun]

My kids will go nuts seeing your suit.

[s1l3nt]

Looks the good as usual Bazza! Well done.

[AsignObservatory]

My kids will go nuts seeing your suit.

That's the idea mate! I hope they do!!! :D


Looks the good as usual Bazza! Well done.

Thank you sir!

Baz.

[Canonball]

You sir, are a genius! this post could easily have it's own blog with millions of followers! Plus this could be added on things to do while in Canberra, check out an Iron Man suit & visit the observatory

[AsignObservatory]

You sir, are a genius! this post could easily have it's own blog with millions of followers! Plus this could be added on things to do while in Canberra, check out an Iron Man suit & visit the observatory

Thanks mate! Wouldn't that be grand!?

Thanks to my friend Shane again, for making such a big effort to be my J.A.R.V.I.S tonight.

The suit was a little easier to move in, but we identified more places for improvement. This time it took an hour to suit up, photo-shoot in every angle, with and without flash, then de-suit. We are getting better!

The gap between the top of the legs and the bottom of the codpiece is much less now which just looks great! The arms now just clip on instead of having to screw together both at the elbows and at the shoulder bells. The trimmed-down neck allows for head movement now bus still needs a little more off it. The cuff on the right arm needs reshaping slightly to get my thumb joint out. Took a little skin off tonight, forgetting that when you heat up, you expand.

Lighting in the chest is fine, but it is quite obvious that the eyes are FAR too bright so will need resistors or a total rethink. Shoulder bells keep slipping below the edge of the shoulder at the torso, so I will be welding on a couple of flat hooks for them to hang off, yet still pivot from.

Back profile - Some big gaps in the armour here to be covered with either coloured foam or shiny red leather layered plates.

The hand plates and the achilles flight-control flaps need spring tensioners to return them to the closed positions once activated.

2nd full suit test fit and walk around. Better. Much better proportions in the legs to torso now.

Walking is OK, need to practice to get used to it but the arm movement is limited. I'm not sure what more I can do to fix that. Might just have to live with it.

http://i.imgur.com/WW09LTE.jpg

http://i.imgur.com/fam5VNf.jpg

http://i.imgur.com/w8oOKOQ.jpg

http://i.imgur.com/pv1Uj7a.jpg

http://i.imgur.com/5tRl7m9.jpg

[AsignObservatory]

http://youtu.be/V5fQqofiNoY

[Glen1]

Looking good mate. You do realise though, if you put on any weight you'll have to get a panel beater to 'let it out' for you?

Regards
Glen1

[AsignObservatory]

No Need, I have designed it so I can add expansion plates. Besides, once I get off my arse and wear this to a few events, I'm more likely to lose weight through exertion and sweat! :P

Here's two pictures showing the hand plate in the open and closed positions. I still need to refine them, take the inside corner off and pad them underneath, but the hinge will have a switch under it that activates the hand repulsor illumination when it is pushed back by the back of the gauntlet.

There will be a return spring tacked on the inside as well to bring it back to the closed position snug against the back of my hands.

http://i.imgur.com/mwwei8H.jpg

http://i.imgur.com/MrhVH0k.jpg

[AsignObservatory]

Today I had little time during lunch so I just added the toe recesses. I cut the rectangle out of the front of the toes, then made two small trays the same size as the hole about 5mm deep and tapped them in for a snug fit. I then set the MIG to low wire feed and enough juice to penetrate the .95 sheet and fuse them together.

A quick grind and you get the idea. More refined clean-up later.

http://i.imgur.com/9FWYc3Q.jpg

[Redgums]

Sorry, mate! More work for you I'm afraid!

Can't post the link but CNN has a story of interest to you today about a Zgerman fan's Iron Man suit glove build.

[AsignObservatory]

Sorry, mate! More work for you I'm afraid!

Can't post the link but CNN has a story of interest to you today about a Zgerman fan's Iron Man suit glove build.

Can't find it.

[ameerat42]

Can't find it.
This: http://www.blastr.com/2013_1_22/omg_iron_man_fan_makes_working_gauntlet_armor_shoots_lasers ?

[AsignObservatory]

This: http://www.blastr.com/2013_1_22/omg_iron_man_fan_makes_working_gauntlet_armor_shoots_lasers ?

Ah yes. Saw that one a long time ago. A bit kitchy but fun. Thanks for the link.

Baz.


Update: Went to the powdercoaters today with the suit to come up with a plan. Basically because of the filler I need to use to smooth out imperfections and the temperatures required in the powder coating ovens, I can't powdercoat and must go to the auto-paint option.

Bummer. He was prepared to powdercoat for free as long as I paid for the powder. :2blue:

[AsignObservatory]

Canberra Times article. It will be in Sunday's paper. Hopefully with more pictures.

http://www.canberratimes.com.au/national/iron-man-embraces-steel-to-warm-kids-hearts-20150711-gi924p

[Mark L]

All the best with the soon to be twins.:th3:

[AsignObservatory]

All the best with the soon to be twins.:th3:

Thanks Mark. :th3:

[ricktas]

http://www.abc.net.au/news/2016-01-22/canberra-dad-recreates-iron-man-suit/7105426

[Debra Faulkner]

Awww, wow, good on him/you, Bazza!!!!!!!!

It certainly has been amazing seeing the occasional update of the 'suit'.