Ironman mark 42 build.

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Rancid Musk

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I was able to finish my Spartan build just in time for Halloween. After months of work it all came together. Afterwards I was itching to start something else. My buddy asked me to build him the Mark 42 Ironman suit. After some negotiation I agreed to this kinda commission build. My timing is August next year and he would help on the electronics. Plenty of time and low stress. I was always drawn to War machine so my plan is to learn as much as I can from Ironman then build War Machine by December 2014.

The Build is on!!!!

I am not as familiar with the the Mark 42. I am using a bunch of different files because I can't seam to find a complete set of Mark 42 files that is not foam. I am using the arms and legs from Skyline MarkVII

The helmet is Mark 42 by Blackouts unfolded by Streetsoul.

I started with a tester helmet to get the size. After 2 revisions my buddy was happy with the size (200mm ear to ear). I pepped and resin the helmet. The eyes were crazy and required a lot of patience.

Thanks to Sandbagger for his awesome posts and pics. Helped me a lot to plan this build.

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After a week of bondo/sanding here is my progress. Managed to get the face part apart and hinge the back. The moment of truth came and the helmet fits. I have some more sanding to do but it is coming along nicely.
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I finished the helmet. This was a lot of fun to do. The Client is very happy. He wants to do the eyes. He may want to do the motorized faceplate but he is not mechanically inclined so I may end up doing it. I already have ideas.
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The Rivots worked really well for pivot points. They where tight at first but with a little WD40 and elbow grease the action is very smooth.
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The Face plate is ready for motors.
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I went through a few revisions of the abs. I ended up trying something new. I took plastic sheets and layered them instead of foam. I had problems with the glue holding. I tried several. I ended up using pop rivet to hold everything. The other problem I had is the client is bigger than me in the middle. I wanted to do the abs before scaling the chest and back.
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It was a convention month so I took time off my build.

I got the chest and back pepped and hardened.
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AHH. First warm(ish) weekend we have had in months. I can finally bondo without my fingers going numb.

Took advantage of the nice weather and bondo/sand the chest and back.
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It is fraking cold again. It is 5 degrees in my garage. Bondo is at a standstill. I did manage to install some electronics in the eyes. I used regular safety glasses and placed veil material behind it. A row of 10 surface mount LEDs line both top and bottom of each eye. I tried mirrored sun glasses first. It worked but visibility was low. Safety glasses works much better.

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This build got me suit envy since it is for someone else. It has got me motivated to star my war machine sit. Can't have my friend have all the fun.

Managed to get both legs peped and resined .
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This looks awesome! Looks like I need to apprentice to learn some bondo work :) Pretty excited to see where this goes and to see the start of your war machine.
 
Busy week. Is managed to get both legs hardened and 1 leg bondo- ish. I added metal hinges with binding posts instead of the peped ones. The legs kept snapping on. Me when I bent my legs.

I ran out of primer and had to switch. For bondo work, definitely recommend getting a palm sander for rough sanding and a second sander with a nose attachment for fine sanding. It has cut my sanding time in half. Also after fine sand spray "wet sand able" primer and then do a final sand with a hi grit paper. I find that the regular primer is too gummy and does not give the final finish I like.

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I Finally got the Face plate motorized. It took me several revisions and a lot of frustration.

Bottom line: Cables bad, Rods or Solid links Good.

I tried Lawnmower cable, 2 different gauge Piano wire, aircraft cable but the results were the same. Wire can pull very well but pushing is difficult. Either it lifed but could not close or closed and only lifted half way.

I wasn't until I switched to a solid Link that I got somewhere. I started with 1 servo located in the jaw pushing a sheet metal linkage. Worked but at 33 oz @ 6 volts the servo was straining.
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I added a second one on the other side to give it more. As the battery diminish I didn't want it to stall out.
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Here is an inside shot. If I Added video googles I will need the extra force.
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Here is the arc reactor I wanted to do
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Used solidworks to creat a .stl file
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Got to play with a 3d printer
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Final paint
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I ended up using the white plastic lid of a bondo container to defuse the light. Used neopixle ring behind for light.
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That arc reactor looks dead on accurate. Great job for your build, im sure the client will love it. Its good that you worked out your mechanical issues with the faceplate. Cant wait for more.:)
 
Good to see you are making progress! Love the details! We move in a few weeks so once that happens, i will be spamming your inbox :p Great work!
 
Good to see you are making progress! Love the details! We move in a few weeks so once that happens, i will be spamming your inbox :p Great work!

Happy to share. Good luck with the move. I heard awesomecondc was awesome from some of my friends.
 
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