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Awesome Ironman Costume Ever

This is my Iron Man Mark 4 costume from the Iron Man 2 movie. I have always liked Iron Man, even before it was a movie.

  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever
  • Awesome Ironman Costume Ever

I attempted a costume once, when I was young, and everyone thought that I was a power ranger because no one knew who iron man was (since if it’s not a movie, it doesn’t exist. ha-ha). This time around thought (thanks to the movie) people thought it was the coolest thing ever! Almost every single person thought that I had bought it. They were blown away when I told them that I had hand made everything. I had a following of little kids at the party I took it to on Friday. When I revealed it to everyone, by walking into the party with it on, I got wide eyes and jaw drops from every single adult with a bunch of them saying “Holy crap it’s the real Iron Man!”

The suit is made with thick EVA foam (same as craft foam) and hot glue. I used a paper pattern to cut every single small piece and hot glued it together like a giant puzzle. There were hundreds of small pieces glued together to make the suit. I also used a heat gun to give the foam curve where it needed it. I then spray painted the armor with plasti-dip, then primer, then auto body paint, then a gloss spray. I soldered the lighting system for the eyes, the hands and the chest piece. The chest piece is actually the bottom of a Gatorade bottle with speaker wire. The hands light up when I lift them up as if I’m shooting something. The arms and legs are held in place with a nylon strapping harness system I made that I wear underneath the armor. The suit is actually quite maneuverable and not uncomfortable to where. I just can’t sit while wearing it. The chest piece is actually the bottom of a Gatorade bottle with speaker wire.

I have been making this Ironman costume for 14 months in preparation for this Halloween, starting last September and finally finishing this Monday (10-26-2015). I’m guessing it was at least 250 hours, probably more (working on it a few hours a week) I have actually never made a costume like this before, so this is my first time doing something this intense. Hope you enjoy it!


Last Minute Homemade Ironman Costume

This started because I wanted to be Iron Man for my birthday party/ costume party. I purchased an Iron Man costume online and it was so cheap looking I could not bear to wear that to my party especially because it was MY birthday and I would be the center of attention. I had to dress to impress.

  • Last Minute Homemade Ironman Costume
  • Last Minute Homemade Ironman Costume

My uncle makes excellent piñatas and is very creative so I got the idea to ask him to help me make the costume 2 weeks prior to the party. My uncle did most of the designing but I directed with the specific details. It was done with trial and error in the beginning with getting the correct size ratio – LOL – the first helmet he made was kid-size.

The pieces were cut with his Cricut machine out of cardboard and the use of special software. Then he traced the pieces onto foam and cut them out. Then pieces were adhered together to make 17 larger pieces. My uncle painted the suit as well.

Together we figured out the arc reactor and the lights for Iron Man’s hands. Underneath we decided I was going to wear a black spandex suit so that my skin did not react to the foam. The day of the party it took about 1-2 hours to Velcro all of the pieces together. When I made my appearance everybody loved it especially because I was acting the party. The funniest part of the whole night was that I could not see a thing so I ended up bumping into many people.

*PS he made a batman costume for my cousin as well :-)


Coolest War Machine Ironman Costume

This has been the hardest but the most funnest costume I have ever made. I started it 4 months before Halloween, most of which was done at work (which I shall call jo’s car rental).

  • Coolest War Machine Ironman Costume
  • Coolest War Machine Ironman Costume
  • Coolest War Machine Ironman Costume

I had watched video after video of how to do this with so many different mediums. But money rendered me to do it as free99 as I could… soooooo bring in the cardboard from the shop down the street, a few rolls of duct tape and some spray paint.

I slowly worked on it starting with the chest piece, knowing that this was the center of attention. Only to realize 8 weeks later I dad 4 more weeks to do everything else. Might I add that having a dummy to be your model and not your buddy who is half your size will help. The forearms and biceps were a breeze. The cod was well awkward! Nothing like wearing an adult diaper made of hardened cardboard. The legs and boots were done frantically the night before Halloween, along with the painting and my wife’s costume.

When we showed up to our first party the kids went wild… along with the adults. Many of the kids thought I just might really be Iron man! I assured then I wasn’t, and in fact I was War-machine!


Coolest DIY Ironman Costume

I have been working on this Ironmand costume for over a year and a half now and I love spending time on this project.

  • Coolest DIY Ironman Costume
  • Coolest DIY Ironman Costume
  • Coolest DIY Ironman Costume
  • Coolest DIY Ironman Costume
  • Coolest DIY Ironman Costume
  • Coolest DIY Ironman Costume
  • Coolest DIY Ironman Costume

I think one of my favorite things about this suit is how much I make people’s days when I walk around with it on. I built the costume because my 5 year old nephew and I were watching the Avengers and he thought it would be so cool to have the suit and I thought, “yeah it would be.”

I tried to determine the best way to create this costume and found a unique way of building it. That way was out of flexible foam and 3D programming. I made a 3d scan of my body and then scanned a suit from the movie and layed it over the top of my body on the computer. Next, I placed it in a 3D program for origami and I made templates of each piece, cut those out, laid them on the foam mats, and cut them out on those. Then I hot glued it all togther which was easier said then done.

The helmet was one of the hardest things to build. It is the focus point, so I had to make that incredible. I used sunglasses and LED lights and wired them to the helmet while making a coat wire hanger into hinges for the face plate to open and close.

Then, I sprayed the whole thing in Plasti Dip which is a rubber coating. I painted it and wired electronics from headlamps for the hands. I also took a old Axe hair gel container and made the arc reactor in the middle. I used silver acrylic paint all over it to give it the battle damage that makes it look like steel. It is always super funny when I see people come up just to touch me and see if the suit is steel. Ha ha!

I won a costume contest at the Legacy Initiative in Utah which was super fun to be apart of.


Awesome Homemade Ironman Costume

This Ironmand costume was was born when I was asked to participate in a costume bike ride. I was already looking into people making these amazing Iron Man costumes, so this was my chance to make one for myself!

  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume
  • Awesome Homemade Ironman Costume

I started with the helmet and made it using a program called Pepakura which allowed me to make it out of card stock paper. This phase of building the helmet took a very long time: around 7 hours to cut all 101 pieces out then to build it it took around 10 hours.

The next thing to do was to harden it with fiberglass and then eventually smooth it down with bondo (car filler). I liked how my helmet came out from the paper phase so I began building the rest of the suit out of foam to make it faster and cheaper. Once I had all the pieces made which took a grand total of 3 months to build, I coated the pieces in Elmer’s glue which I found a Gallon of at Walmart. This made the surface of the foam smooth so that I could paint away!

I finished painting and started coming up with ideas to put lighting in the suit including the eyes, chest, and hand repulser lights. This was very successful for me and I got all the wiring done with the help of my father. In the hand lights we also included a mercury switch that my dad got from a friend at work which made it so when i lifted my right had up my lights would come on in the hands to save batteries and it was so cool! I FINALLY finished the strapping system the day before I was to show it all off at our first comic con in Salt Lake City in Utah. It had made the whole thing worth the time spent making it.

I got smiles from hundreds of little kids squealing IRON MAN! The only thing I missed out on was the Cosplay contest which Iwas very bummed about. :( So i entered into the Fan X comic con cosplay contest near the End of the school year and had an absolute BLAST! It was a great feeling to go on stage and show all those people my costume!

More Ironman Costume Ideas

Take a look at all the Ironman costume ideas on the site.



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