Coolest Homemade Child's Iron Man Costume - Progress
Coolest Homemade Child's Iron Man Costume - Jet's On
Coolest Homemade Child's Iron Man Costume - Side View
Homemade Child's Iron Man Costume:
Materials - Cardboard, Foam sheets, Paint (Maroon/Gold), Hot Glue, Sweat pants, Hooded Sweat Shirt, Push Light, Tea Lights, Old Hockey Helmet.
Using cardboard I cut out the shapes needed. If the piece needed to be curved I would score the cardboard and bend it on the cut. Worked well. After painting I hot glued the pieces to an old black sweat suit. We reversed the top of the suit so that it would zip up in the back not only to make it easy for my 5 year old to get in and out, but also to have a seamless front plate.
I used foam sheets on the back of the legs, bottom and back. This covered a lot of area and made it easier for my son to walk around. Also used the foam sheets to cover his shoes. All the cardboard cut outs and foam sheets were super glued to the sweat suit and held up very well.
The light in the center is a push in closet light that we could use to light the way and made it easy for him to turn off and on. We had flickering tea lights velcrod on the palm of his hands to give the illusion of powered flight.
The helmet was an old hockey helmet that I tore the foam out of and painted. Using the adjustable strap from the back I hinged it to the front that allowed the face plate to be moved up and down. My son had a great experience as did Dad getting to spend some great quality time with him while making it.
I started this Homemade Ironman Halloween Costume on a whim in May 2009. My idea was to build a movie-accurate Ironman suit for my four year old, complete with working LED chest piece and glowing eyes.
The process began by building a paper model of each part which was subsequently fiberglassed on the inside to provide rigidity. Body filler and shaping (oh so much shaping was the next step and ultimately became the most time-consuming part!). Each prototype piece was shaped by hand with some assistance of a dremel tool or hand sander.
Once all the prototype parts had been constructed, I proceeded to build silicone molds with a plaster outer shell so that I could case urethane plastic pieces which would be hollow and very light weight. Once the pieces were cast, sanded, primed, and painted, a harness system was created and installed as well as copious amounts of Velcro to keep all the pieces attached.
I've been working on this Homemade Ironman Halloween Costume Idea for about a month. It is made entirely out of cardboard and poster board. I rewired a few LED Lights and was able to activated them at will.
I took the costume around Chicago and got a lot of positive feedback from it, even won a few contest.
I am not a professional so this was all completely new to me. I am very proud of how my costume turned out. Let me know what you think.