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Jordan Chapman, AKA Graphic Jordan, over at the RPF has been working on a custom build of the Iron Man Mark VI costume from the ground up since February 2011.
Jordan is using 4mm thick EVA foam rubber to construct the Iron Man Mark VI suit from scratch. To create curved pieces, he cuts slits in the foam and glues the pieces back together on the edges. That description doesn’t do his work justice because if I followed those steps I’d followed those steps I’d end up with a big gluey foamy mess.
I love how he’s spent so much time developing this over months of work. Apparently this is Jordan’s second Iron Man costume build, and he’s pulling out all the stops on this one.
Here are some current pictures of his progress:

Full shot of costume

One of the arms with a preliminary paint job
You’ll have to follow along on the forum thread to see the finished product though. These things take time! If you’d rather not wait, you can check out the Iron Man costumes already available on the website.
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