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Iron Boy Costume

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35 votes
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Iron Boy Costume

Iron Boy

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Photo #1 - Iron Boy Photo #2 - Iron Boy Photo #3 - The foam covers are attached to an aqua-shoe. All he had to do was slip his foot into it. Photo #4 - Iron Boy
Costume type:  Costumes for Boys
Categories:Halloween Costumes, Movie and TV Show Costumes

This homemade costume for boys entered our 2012 Halloween Costume Contest.

A word from Nelson, the 'Iron Boy' costume creator:

My family and I decided to go with an Avenger's theme this year, with my youngest wanting to be Iron Man. The armor is being worn by my youngest son, who is 5 years old.

The body armor was made using craft foam and put together with hot glue. I sealed the foam with Modge-Podge then spraypainted it with a latex primer and paint.

The helmet was made using foam and sealed with Modge-Podge, however, I needed a bit more stiffness for this piece so I coated the outside using automotive expoxy resin. I then used bondo, sandpaper, & a lot of elbow-grease to smooth it out. The inside of the helmet was hardened using resin and fiberglass. The chest lights up by way of a tap-light.

The shoes were the most challenging part of the project. I used an aqua shoe (the king you wear at a pool or at the beach) and attached a foam cover I made using shoo-goo glue.

Overall cost of the project was $200-250. Time spent was 40 hours. Satisfaction at seeing his face when he first put on the armor, priceless.

Rating: 4.8 of 5. Votes: 35

35 votes
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Comments

#1 comment by louise November 1, 2012

That is the toughest, shiniest, fiercest Iron Boy I EVER saw!

#2 comment by Pat Fuchs November 1, 2012

Awesome costume! a lot of work, well done!

#3 comment by Christina October 18, 2013

OMG, that is amazing. My son would FREAK over this costume! MAJOR Kudos to you!

#4 comment by Monique November 27, 2014

This is an awesome costume! I have never seen anything like this!

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