This build started off as a challenge actually. Originally I gave myself a total of 1 week to get an entire foam suit together (excluding the helmet).
In the end, I managed to get everything, including the helmet done in 3 weeks.
So, progress pics. Unfortunately, there aren't many, but I will be more than happy to answer questions.

Starts off with a chest piece. EVA foam with craft foam for details.

Getting the base pieces done. This took me about 3 days to get together. Those abs you see there are NOT the final abs I had. I actually re-did the abs at one point.

Moar progress, gloves and arms done.

Helmet, post-Body filler and detailing. Bondy Spot putty was a lifesaver here. I also found out that the cheapo wood filler stuff serves it's purpose REALLY well if your piece is solid enough. There's about 3 layers of Rondo for the inside. The ears are NOT bondo. What I did was I went to the Dollar tree, grabbed some $1 trash cans, cut them into circles, and glued them to the helmet with GOOP Glue.

Arc reactor. MAJOR thanks to STEALTH here, Prewired LEDs with Resistors saved me a bunch of time and headache. Arc reactor was made with a sink drainer, some transparent bins found at the Dollar tree, hot glued together with a Nylon Mesh from a White Laundry bag to keep things in place.

Getting everything together. I was originally planning on crashing RTX with this, but I found out tickets were sold out. This made me sad. The paint you see is cheapo Latex paint. Which works REALLY well, is shiny, and adds another layer of sealant to your foam build. I wouldn't recommend using straight up latex paint as sealant though.

Finished product. Photo credit: Dragon's Lair Comics Austin.

Photo credit: Dragon's Lair Comics Austin.
Well, that's that. Sorry for the lack of pics, but I'm more than happy to answer any questions yall might have.
In the end, I managed to get everything, including the helmet done in 3 weeks.
So, progress pics. Unfortunately, there aren't many, but I will be more than happy to answer questions.
Starts off with a chest piece. EVA foam with craft foam for details.
Getting the base pieces done. This took me about 3 days to get together. Those abs you see there are NOT the final abs I had. I actually re-did the abs at one point.
Moar progress, gloves and arms done.
Helmet, post-Body filler and detailing. Bondy Spot putty was a lifesaver here. I also found out that the cheapo wood filler stuff serves it's purpose REALLY well if your piece is solid enough. There's about 3 layers of Rondo for the inside. The ears are NOT bondo. What I did was I went to the Dollar tree, grabbed some $1 trash cans, cut them into circles, and glued them to the helmet with GOOP Glue.
Arc reactor. MAJOR thanks to STEALTH here, Prewired LEDs with Resistors saved me a bunch of time and headache. Arc reactor was made with a sink drainer, some transparent bins found at the Dollar tree, hot glued together with a Nylon Mesh from a White Laundry bag to keep things in place.
Getting everything together. I was originally planning on crashing RTX with this, but I found out tickets were sold out. This made me sad. The paint you see is cheapo Latex paint. Which works REALLY well, is shiny, and adds another layer of sealant to your foam build. I wouldn't recommend using straight up latex paint as sealant though.
Finished product. Photo credit: Dragon's Lair Comics Austin.
Photo credit: Dragon's Lair Comics Austin.
Well, that's that. Sorry for the lack of pics, but I'm more than happy to answer any questions yall might have.
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