Coolest DIY Iron Man Costume

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

Coolest DIY Iron Man Costume

Coolest DIY Iron Man Costume

Coolest DIY Iron Man Costume

Coolest DIY Iron Man Costume

Coolest DIY Iron Man Costume

Coolest DIY Iron Man Costume