Stage 5 – Flexible Pieces

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/

Stage 5 – Flexible Pieces

Foam abs and obliques

Materials I used:

• EVA foam
• Exacto knife
• Exacto board cutter (for angled cuts)
• Modpodge
• Plastidip
• Automotive Adhesion promoter
• Automotive spray paint
• Krylon Low Oder Clear Finish (gloss)
• Chip brush

Steps:

1. I used form for pieces that I felt would need more flexibility. I used the foam method for the hands, abs, neck, and codpiece.
2. You can google foam templates for various pieces which you will print and cut with Pepakura Viewer.
3. Once I printed and cut the template, I traced onto my foam pieces.
4. Using references pictures of the part I was trying to build, I varied the angle of cuts in order to get the appropriate shape for when the piece is glued together.
   

   Foam Neck

5. Once the flexible pieces were build, I sealed the foam with a layer of modpodge, then 3 coats of black plastidip
6. Automotive adhesion promoter was then applied in 3 coats, then the sprayed with color within10 minutes of the promoter drying
   

   Foam Torso Painted

7. After the color paint was dry, I used the Krylon gloss to give the pieces some shine
8. I then weathered the pieces as previously described
   

   Comparison
   Thigh – Fiberglass
   Gauntless – Foam

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