Home » Character Costumes » Animated Character Costumes » Iron Man Costumes » Coolest Iron Man Halloween Costume

Coolest Iron Man Halloween Costume

This Mark 3 Iron Man Halloween costume is based closely on the the movies. I spent lots of time trying to get all the details in.

It is mainly made of Poster Board, Foamies (arts & crafts thin foam sheets), a ton of Hot Glue(I think I used 140 sticks or so including the helmet and arc reactor), and Mod Podge for the body. Mod Podge was used to seal the foam to make painting easier and to strengthen the poster board and seal that as well. The entire construction of the costume took about 1 month on and off or 100 hours of labor. Most of the time was spent test fitting and cutting templates that fit me correctly.

The Arc Reactor was made by following the Instructables Arc Reactor DIY using surface mount LED’s and molding plastic.

The Helmet took about 40 hours of work (including drying,sanding,bondo, and painting). It was made by first creating a mold of my head as the base using Plaster Bandages you can get from arts and crafts store (Plast’r Craft is the brand). Once this dried I built up the Iron Man Mark 3 shape by using a very thin aluminum mesh(held down by hot glue) you can get from arts and crafts stores as well near the clays. Once you think you have the shape down, lay down more plaster bandages. Then, cover the outside of the helmet with bondo in small increments, sanding in between each application to a smooth finish. After that is just painting.

Painting was done using a Gloss Colonial Red and a RustProof Metallic Gold. 3 coats for body and 6 for helmet for an extra shine.

Iron Man Costume

Iron Man Costume

Coolest Homemade Costume Contest 2023

2 thoughts on “Coolest Iron Man Halloween Costume”

  1. I wanted to tell you that I think you really knocked that one out of the park. Looking at the costume, you put your own little spin on the design, which was original, yet still extremely comparable to the movie version in terms of positioning and location.

    Nice job!


Leave a Comment