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Iron Man - Hulkbuster Costume

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12 votes
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Iron Man - Hulkbuster Costume

Iron Man-Hulkbuster costume

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Photo #1 - Iron Man-Hulkbuster costume Photo #2 - Iron Man-Hulkbuster costume Photo #3 - Iron Man-Hulkbuster costume Photo #4 - Iron Man-Hulkbuster costume Photo #5 - Halloween night Photo #6 - Halloween night Photo #7 - Halloween night Photo #8 - test fitting on 10/17/2015 Photo #9 - Making adjustment to the visor motor Photo #10 - Final test fitting before painting. 10/31/2015
Costume type:  Costumes for Boys
Category:Halloween Costumes

This homemade costume for boys entered our 2015 Halloween Costume Contest.

A word from Fred, the 'Iron Man Hulkbuster' costume creator:

Designed a homemade costume for my 11yo son inspired by the summer movie "Avengers: Age of Ultron". We started with a round swing top trashcan from home depot ($13) for the body and built everything around that. We started building on 10/3 and did everything in less than a month. Features include: 1) Motorized flip-up visor 2) Fingers/hands open & close 3) Activate repulsor lights in palms 4) Authentic battle damage

We've built halloween costumes for the past several years and this one is clearly our favorite & most impressive. Materials used were misc boxes, mailing tubes and 2 empty gallon-size apple juice bottles. To rig the visor to flip open, we used a spare lego technic motor w remote.

Purchase list: Round trashcan w swing top lid ($13), foam piping insulation ($5), spray paint ($15), masking & colored electrical tape ($10), small flashlights ($12), zip ties ($12). The most expensive part was the Lego Technic Power Function kit w IR remote ($60) but we already had that. Everything else we had spare around the house.

Rating: 4.7 of 5. Votes: 12

12 votes
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#1 comment by Shannon Lee October 23, 2016

Like! Trying to recreate for my little boy this year! Can you elaborate on how you were about to use the lego technic power function to raise and lower the visor? I have the same but have no idea how to create the pulley. Thanks in advance! Great costume!

#2 comment by Fred October 24, 2016

Here is a test video I made of the flip up visor.

Here is everything I used.

8884 IR Receiver, 8886 Extension wire, 8883 Motor, 8879 IR Remote Control, 8881 Battery box, 8870 Light

1) The motor in attached to the back of the helmet on the inside
2) The motor is attached to a spool with picture frame wire wrapped around.
3) The wire is running through a straw secured along the top inside of the helmet.
4) Finally the wire runs out the top of the helmet between the seem & is connected to the front middle (bridge of the nose) of the visor.
5) The IR receiver (connected to an extension wire) was hidden on the back of the costume facing outward through a hole where I could have a direct line of sight with the controller & operate it.

My son wanted to operate the visor through a switch but he had difficulty operating the switch hidden inside his huge hands. We reluctantly decided on the IR remote so I could operate the visor for him. Be aware the motor creates a high pitch whine when triggered that he found really annoying. It was probably very loud inside the helmet. If I had more time I would have tried to muffle the sound. Deadlines.

Good luck. Make sure you post photos/video when your are done. If you have any questions, let me know.

Video of costume unpainted.

Video of finished costume.

#3 comment by Shannon Lee October 24, 2016

Thanks so much! Not sure this Mom can pull off the same as you did we may end up using old fashioned pulley system if I can't have success with the method you used. Thanks so much for the tips... it's coming together but the face mask moving up and down is yet do be done. I'll post pictures, we have used your general design and made a few tweaks. Thanks again!

#4 comment by Anita October 13, 2019

Hello Fred! Amazing costume and my son fell in love with it! Do u by any chance have a step by step for the costume? Would love to recreate for an avenger living boy!!

#5 comment by Fred Zimmerman October 18, 2019

Hi Anita,

I haven't posted detailed instructions on how we made the costume but there are some youtube videos of it in progress.


if you have any questions, feel free to reach out.

#6 comment by Anita October 22, 2019

This is seriously so amazing and inspiring Fred!! thank you so much for sharing!!

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