My 1st Build Iron Man Mark 47 XLVII Foam Armor

my sealed and painted foam ironman arm
arm_zps51cf0e22.jpg
 
I understand that but I was thinking about making a mold out of this too and was thinking that if I could fix it up to look a little bit better before I make the mold for less work later with the cast


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if your not wearing the parts and going to make a cast of it you probably could get away with resin and bondo. smooth on makes an epoxy foam sealer. start with that but let the stuff dry for a week then coat it in resin. you will want to do the front and back. then bondo away!!
 
Cool then I'm good to go I'm also gonna remake the helmet in foam again tomorrow as well but Until I get the leg Abs Shoulders And Biceps files this will give me something to do in the meantime and it will give more time to practice using Bondo,Rondo and fiberglass as well as making my first mold and cast so its a win win for me thanks for that tid bit of info bro much appreciated i can't wait to start this tomorrow


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Can Bondo or Robdo Be Applied to Foam ?

yes, it is, but based on my experience here's i've done. . .

i did fiberglass foam helmets btw. . :lol in this method, fiberglass first the inside. .then cut the helmet's faceplate and the lower back section of the helmet. . .then seal it first, either with plastidip or PVA glue, i'm using acrylic emulsion to seal my parts. . .then after you have sealed (i think 2 for plastidip, 4-5 layers using PVA glue) the helmet, apply bondo regularly. . .then sand. .sand. .sand. . .take a break and a cup of coffee. .then sand again and again until you are satisfied with it. . .

note: it will make your foam helmet heavy. .mine's round 1.25Kg? :confused i think you can do it without fiberglassing the inside. . .just seal it then apply bondo. . .
 
yes, it is, but based on my experience here's i've done. . .

i did fiberglass foam helmets btw. . :lol in this method, fiberglass first the inside. .then cut the helmet's faceplate and the lower back section of the helmet. . .then seal it first, either with plastidip or PVA glue, i'm using acrylic emulsion to seal my parts. . .then after you have sealed (i think 2 for plastidip, 4-5 layers using PVA glue) the helmet, apply bondo regularly. . .then sand. .sand. .sand. . .take a break and a cup of coffee. .then sand again and again until you are satisfied with it. . .

note: it will make your foam helmet heavy. .mine's round 1.25Kg? :confused i think you can do it without fiberglassing the inside. . .just seal it then apply bondo. . .

Thanks for the bro I was mod podgeing the hell out of it now I have a better idea of what to do

And as for the templates I bought them from IMIM2 and labsics helmet


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I've been longing to ask and share foam+resin too.
This is what I did:
1. Foam was sealed with PVA. Inside (only for FB) and outside (all parts)
2. On thigh, I FB'd the inside.Later on I found out that the FB didn't stick to the foam. I am not sure what went wrong, but I ripped out the FB afterward.
3. I resined the whole parts 2/3 layers.
4. The foam is sturdier, but it'll crack here and there only 1 wear, and cracks even more after some time (I only wear my suit once!).

So I don't think foam+resin will do, however, I am thinking about resin on the outside (or maybe inside) without sealing it first. In that way the resin will soaked into the foam, make it more rigid? It will requires more layers of resin.

Bondo will crack when applied on flexible structure. I don't think foam+resin is rigid enough. Foam+fb maybe better for bondo.

Are these points valid?
 
I'm making mine out of interlocking floor mats as well. People say that it can't be done, but I feel that using the half-inch foam works just fine. I will need to go back and fill in the open pieces with 4/6mm foam.

I have one question: how did you apply the sealent? Did you brush it on or was your aerosol? I'm almost halfway done with mine and need to look into sealing it. Thanks!
 
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