Pepakura. You need to download both the viewer and designer.

Tutorial: Simple Armor Scaling

Some tutorials I made on techniques I use. I hope to get some more done as not everything is covered in them. There are many others if you look around.

Dracks Foam Technique Tutorial Part 1

Dracks Foam Technique Tutorial Part 2

Nice set of techniques by JFcustom Here

A great tutorial on using the pep files for foam builds. XRobots - How to modify pepakura templates for foam

For the lighting in the suit.
Electronics Tutorial by Xrobots.

List of materials, links are UK based. I am sure you can find all these things in other countries but I thought it would be good to throw this info in the thread as a guide on what you need to make a suit of your own.

1. Foam Mats 10-12mm thick. I got a better deal than this. They seem to have gone up in price, Camping Mats 5-6mm thick & Craft Foam 1-2mm thick

2. Blades. No.11s. You can get the handles here too. Also you can get cheaper blades on ebay but they snap easy and blunt easy. Swann Morton are the best I have found so far so sticking with them.

3. Glue gun I use & glue sticks.

4. Plastidip. Used for the first undercoat to seal the foam and give it that smooth base ready for part 5.

5. Primer car spray and then the spray/paint you want for your finished paint scheme. Finally some lacquer to protect your piece and make it nice and shiny.

6. Webbing & Buckles for strapping.

7. There are many more materials I use/used but as you build your armour you will work out the bits needed for those extra touchs.

8. Moulding Optional but thought an armour moulding link might help people out wanting to have a go

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Well guys I finally started the foam Ironman MK 5 suit. I was ill at home today and wanted to make something downstairs so I could watch movies with the wife. Got loads of scraps left from my Terminator build so here is what I have come up with so far.