do you have a soldering iron?
all things considered, if he really wanted to be ironman with a metal suit, that would have had to have been started a while ago to get it just right. (i thought a lot about it, started making plans even.)
although you could use large soup cans and coffee tins(?)... tack then together and paint them... heck maybe he could just be the Mach I version Stark used to escape...

then again a foam muscle suit isn't so bad.

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I can tell the difference between punks who need a little lesson in manners... and the freaks like you who would just enjoy it.

look i has 'art' (updated randomly) - http://captaindesertpirate.deviantart.com/