NOTE: This full tutorial has been moved to my new blog at http://www.otakuandfit.com/stealth-iron-man-mk-vi-cosplay-made-w-fiberglass-and-foam-tutorial/

I originally made this post in 2012 for the 2012 Halloween Costume Contest. I surprisingly won one of the Grand Prize slots with this write up! Now that I have established my own blog, I am migrating this post onto here. After reviewing, there is still a lot of stuff I could have wrote about so if any of you have any questions, please feel free to comment and some time in the future I will be posting up more details about stages I feel need more detail.
—
This post outlines everything I did to create my first Iron Man suit with a mechanized helmet. I have always loved the look and concept of Tony Stark’s Stealth armor. This was the first serious costume I ever made and it was a lot of learning through the entire process. Start to finish took me about 8 months during my free time. I’ll caveat that all these techniques or methods are by no means my own and I have learned from many great people out there. I am simply documenting the methods I used from all the wonderful resources out there on there net.
Here is demo video from my first suit up in the armor.

And now on to how I made it!
—