hey guys I'm the Hacksmith. On this episode make it real we're gonna be
building a full metal Ironman gauntlet and it's gonna be complete with one of
Iron Man's most iconic abilities
this video is sponsored by Displate. Get 20% off artwork using my link below.
Hey guys, it's the Hacksmith. The world is a little weird right now with all the
lockdowns and this big pandemic going on. Most of our team is working from home
but Bogdan and I chose to self isolate here together in the shop
So we can keep making projects to make videos for you guys to watch while you stay at home
alright let's boot up
if you're new to the channel, we've done a ton of Ironman projects in the past
from shooting Rockets with Jairus of All, to trying to
fly with model rocket engines. To even making a full metal Iron Man helmet
giving it to Richard Browning of Gravity Industries and trying out his real-life jet suit.
we've even made EDITH glasses too. I think the next step is making a
full metal Iron Man suit, don't you? But a full suit would be pretty complicated so
we should start with something simple like this arm here and since we've
leveled up our stainless steel fabrication skills ever since building
that half scale cyber truck we're gonna be making this completely out of stainless steel.
It's gonna be all shiny just like Tony Stark's mark II suit.
Let's get started with the design.
all right, so the hardest part about building
an Iron Man suit is probably actually designing it. If you look at say this
prop that we have right here you can tell it's all curved features and
complex little things really time-consuming to design but a while ago
I got thinking have you guys ever heard of pepakura? Basically cosplayers around
the world make these amazing Iron Man suits out of cardboard foam and paper
and there are actually designs out there. I actually went and I bought some of
these designs they're actually pretty intricate they're designed to be cut out
of cardboard or foam and then folded together into the shape. Well we have a
plasma cutter which means we could potentially just take these designs and
cut them out of steel and then form the steel to be able to make an actual full
metal Iron Man suit. There's one catch though... they weren't designed to be cut out of steel
these have tabs which use to actually
glue the model together. We can't really do that with steel so we are still going
to have to modify these designs just a little bit before we can actually design
our Ironman suit to be made of metal. But this is a fantastic base resource to
build our model off of you don't have to reinvent the wheel you just have to buy
the wheel and modify it...Know what I mean?
As James mentioned, we've got the pepakura files, but now we'll need to modify them in SolidWorks to optimize them for fabrication..
we actually have multiple marks of Iron Man suits and we're gonna
pull bits and pieces from each suit in order to optimize our fabrication for
example this mark 46 glove has large palm pieces but the fingers are tiny
little squares we don't want to be cutting that much and trying to figure
out which one goes where so instead we'll use the mark 45 fingers which have
nice large rectangles here the DXF in SolidWorks let's start updating the design
throughout the design process I've actually fabricated a couple of
prototypes to make sure that I can bend them just like they do in the model.
Next up we can do the fingers
the fingers turned out to be quite tricky because of the type of bend so I have to make quite a few prototypes
but once I figured out that I can use stainless steel pipe in addition to the plasma cut pieces
I think it turned out pretty good. Next we can do the forearm
now there arm looks a little weird in the model... that's because I haven't modeled every single curve the
other tricky thing with doing the forearm was the scale. Luckily we've got
these prop models which I was actually able to use in order to make sure that
all the pieces fit together and fit on my arm. I'm happy with the design and the
prototypes look pretty good which means the last step is to export these get the
plasma cut and me and James can build the final gauntlet this video is
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I've got the DXF loaded into the Maverick CNC software now we just
got to get the sheet metal onto the bed it'll be ready to cut we're actually
using 16 gauge stainless steel as it should be very strong while allowing us
to still bend it
Wooo! It's done. Let's go fishing
Think that's all them. Let's see. Okay this one goes here... this is the worst puzzle ever
finally that's all of them
alright we finished deburring all 37 pieces there's a lot of fabrication
ahead but basically we're going to break it down into three different parts we've
got the fingers right here which I gotta say I really don't look like fingers there
it's a lot of bending and welding to be done to make those look like fingers
then we have the palm and then we have this entire gauntlet so I'll start
working on the fingers you can start working on the palm and then maybe we'll
work on the gauntlet together after you finish that alright let's get started.
Alright, let's get started on these fingers. so step one is to mark our bend lines.
Now that our lines are marked we can start bending it on the break
all right so next step to get the curve of the bottom part of the finger we're
actually going to make use of some stainless steel pipe
so now that we've got our bent finger put the piece of pipe on the edge we'll
tack this in place with a few welds we'll cut a groove there and actually
bend it down along the fingertip
so we've got them tack welded in place now which means I can start forming the front tip of the finger
so the beauty with metalwork unlike woodworking is if you take out too much
material you know always weld more material back on so it might look a bit
rough right now but we will be able to make this into a pretty nice looking finger.
I hope anyways...
it's not pretty but a grinder and paint
we still need to weld a bit more on the seam and then chop it up into the
individual joints of the finger but before I do that I have another four
fingers to make
the palm actually consists of multiple layers so the first
step is to weld the layers together and then we can start bending them into shape
in order to join the front of the hand and the back of the hand we're going to
start off by bending it on the break and then get it into position with a pair of pliers.
you can see there's actually a little bit of curve in the palm and
geometry there is critical in order to allow the two pieces to fit together properly
last few steps are just a couple of welds around the edges and we should
have a fully completed palm
now that the glove is all welded and ground looks pretty good but it's a little hard to
get my hand inside so just like a plastic replica we're gonna cut the top
open and add a hinge but it's easier to get our hand in
now all you need to do is add a hinge
all right that took forever but finally we have all five fingers done and
they're all cut into individual pieces now the question is how do we attach
these to the glove
you see most Iron Man costumes just use a red fabric glove on
the inside to make it look like it's the full Ironman suit and that actually
brings up a really good question about a real-life Ironman suit how would you
actually have a fully armored hand that actually has mobility and can protect you?
you see this is just fabric here which makes your hand pretty vulnerable
which gave me the idea what if we actually took a chainmail glove then the
Ironman gauntlet would actually be completely armored you know just in case
some samurai attacks you randomly. oh jeez!
not bad but the next question, how do we attach metal to thin chainmail
you might be wondering what I'm doing well I'm actually stuffing kevlar rope into the chainmail
and the nice thing about Kevlar is it doesn't burn which
means I won't catch on fire while I'm welding
you might be wondering how it's possible to weld something as thin as chainmail
well you see I'm not actually welding what I'm doing is brazing using silicon
bronze silicon bronze actually requires a lot lower temperature to melt which
means it can fuse with the base material without actually melting it which means
I can weld any thickness to any other thickness or any material any other
material it's pretty awesome. If you want to learn more about it check out a video by this old Tony.
Just got to grind that off and it'll be pretty little finger
fingers are done just gotta clean them off
now due to some of the more curvy parts of the Ironman gauntlet we're actually
using stainless steel pipe because it's really hard to curve a piece of metal
like that so instead we just cut a piece out of the pipe and now we can weld this
together to make the gauntlet
all right got all the pieces now we just have to finish up the welding
all right it's been almost a month of work but we finished our full metal Ironman gauntlet.
the first step to building a full-metal Ironman suit
but right now it's just armor it's no better than a medieval suit of chainmail
what makes an Ironman suit an Ironman suit is the technology that goes into it
so on the next episode of make it real make sure you subscribe we're gonna be
adding Iron Man's cutter to this but instead of using a giant laser which
isn't really practical we're gonna be miniaturizing our CNC plasma cutter into
this gauntlet which means I'll be able to cut through steel plate just like butter