In the film proper, the whole testing of the wireless suit up. It starts out fine but the pieces start coming in faster than Tony realizes. He handles it at first and even pulls off a badass flip to catch the faceplate...then one of the parts that flew into one of his display cases hits him from behind and sends him and the pieces of the suit flying.
The Mark XLII chilling on Tony's couch. Then Pepper flirts with Tony while he's in the suit. Or rather, while he's not.When he mentions she had a meeting with Killian, the suit turns to Pepper in a disapproving look!
And then Pepper looks back at it, goes "What?" and the armor looks sad and walks off.
Tony leaving Harley behind.
Tony: Wait, are you trying to guilt trip me? Harley:I'm cold. Tony: I can tell, you know why? [beat] Because we're connected. [drives away]
Tony's expression during this just sells it. That wry grin of his is absolutely hilarious.
After saving the crew of Air Force One, Iron Man looks to make sure everyone's okay. When he confirms they are, he turns around to fly away... and gets nailed by a truck. Good thing he wasn't in it.
Tony's waiting and stalling for the Iron Man armor to arrive when he's been captured so he can break free. His antics whilst waiting are hilarious, then become a Crowning Moment Of Awesome.
Guard: How did we end up with this shift?
Even better, it comes after he takes out the guards with only two pieces of his armor and a gun.
When he finally gets outside, he's fully suited up save for his faceplate. Remembers how it beaned him the last time. He quickly grabs it out of the air as it's rocketing toward him and calmly puts it on.
Then when he tries to fly, the thrusters short out, lacking power. Seeing Tony clonk delicately down a flight of stairs in the armor is nothing short of hysterical.
The first time Tony jumps up to take a peek over the crate to see how many enemies they're up against:
Harley: My Mom's left for work already and my Dad went to the store to get scratch-'n-win lottery tickets. He must've won because that was six years ago. Tony:[awkward pause] Which happens. Dads leave, no need to be a pussy about it.
Tony: Well I'll be damned... The Prodigal Son returns... [Mark XLII crashes and breaks into pieces in front of Tony] Tony: ...Whatever.
The after-credits stinger, which has Tony casually telling the film's story to a clearly asleep Bruce Banner, who tells him that he's Not That Kind of Doctor. Undeterred, Tony picks up where he left off and continues rambling.
Bruce: I'm not a therapist, it's not my training. I don't have the — Tony: What, the time? Bruce: ...Temperament.
Bruce dozed off at "going down the elevator in Switzerland", and Tony didn't notice until the very end, he's that self-absorbed. He only realized Bruce wasn't paying attention when he dropped his glasses.
Tony: You walked right into this: I've dated hotter chicks than you. Brandt: That all you got? A cheap trick and a cheesy one-liner? Tony: Honey, that could be the title of my autobiography.
Tony nicknames a Mook "Ponytail Express". The exact character name that said actor gets in the end credits.
Tony begging Maya not to tell him there's a twelve year old kid in her car.
Made even better by Tony's shoulders hitching immediately.
After a particularly intense moment where Tony is investigating the bombings, his doorbell suddenly rings and he sees on his security camera someone at the door. Complete with JARVIS snarking back
Tony: [to JARVIS, exasperated] Are we still at ding-dong? We're supposed to be on total security lockdown! C'mon! I threatened a terrorist! JARVIS: There's only so much I can do when you give the World's press your home address...
Tony asking Pepper why she doesn't walk around in lingerie more often.
Tony tells Maya not to be upset that he can't remember her because he can't remember what he had for breakfast. Without missing a beat, JARVIS informs him, "Gluten-free waffles, sir."
Without any other beats lost, "That was it."
Dr. Maya Hansen calls on Tony, is subjected to one of Tony and Pepper's signature squabbles.
Tony: Yes, that's normal. It's a big bunny, relax about it!
James Rhodes/Rhodey/War Machine/Iron Patriot
Tony Stark - who for years was a weapons designer and international arms dealer and is now a Crazy-Prepared superhero with armour for every combat eventuality under the sun - has very little knowledge on how garden-variety guns work. Made funnier when you realize the guns they're using probably do use the same kind of ammunition... just not the same kind of magazine.
Tony:[to Rhodey] Give me more bullets! You have spares! Rhodey: Mine's a different gun! They're not universal!
In fact if you look closely, they do use the same ammunition; both pistols are 9mm models, meaning they could take the ammo out of one of Rhodey's spare mags to refill Tony's pistol. But given Tony's marksmanship skills, the rounds might be better off right where they are.
Before this the two are trying to sneak onto the gantry crane and Rhodey tells Tony to cover him. Obviously Tony's combat experience lies in his suit so his performance is...erratic (he fires one-handed vaguely in the direction of possible enemies, mostly; compared to Rhodey's precision and discipline he looks like a flailing starfish). A mook spots them and opens fire. Tony tries to shoot back and hits the glass on the spotlight but not the bulb.
Tony: You see that, nailed it! Rhodey: [sarcastically] Yeah, you killed the glass. Tony: I was aiming for the bulb, you can't hit the bulb at this distance! [Rhodey promptly pops out of cover and fires...hitting the bulb in one shot. Then gives Tony a "You were saying?" look.]
The running joke that everyone hates War Machine's name change to Iron Patriot. It mirrors the time when people tried to rename french fries into freedom fries.
Rhodey explaining that 'Iron Patriot' was popular in focus groups, in a tone that makes the lameness of such a defense clear.
Later, he comes into the Mandarin's supposed headquarters, demanding the Mandarin and threatens them all with his arm cannon... then gets a call from Tony. Awkwardly, he tells them he has to take it. It's Tony asking him for his login information for the federal database. Rhodey's password? WARMACHINEROX. When the captives he's holding start laughing, he points his Shoulder Cannon at them without looking.
Tony laughs loudly on the in-car telephone, as Rhodey lightly laughs back... Tony: That is... so much better than Iron Patriot.
Rhodey gets a lot of funny lines. Of particular note is this Adorkable moment after he bursts into a sweatshop while searching for the Mandarin and the workers inside gratefully thank him as they rush outside;
Rhodey: Yes, you're free! Uh, if you weren't before. No need to thank me... Iron Patriot on the job... Yeah...
Rhodey's completely dumbfounded reaction to Killian breathing fire.
Savin's reaction is even more hilarious. When your own right-hand man can't believe what he's just seen, you know it's a funny moment. Throughout the movie, he's been unflappable. Caught in a near nuke level explosion, he walks it off. Discovering his boss can literally breathe fire, that puts him off his game.
Particularly amusing if you remember he's an Extremis subject as well, so his whole look could be summed up as "Holy Shit! We can actually do that?! Why didn't anyone tell me?!"
The Groin Attack from Tony's armor when he tries to get to get the parts of the suit to attach to him.
Any scene with The Mandarin/ Trevor after The Reveal because he is a goofy nobody off camera.
A throwaway moment in his big confrontation with Tony Stark. He makes his entrance from the bathroom, warning his lady friends that the room should be avoided for a while. A short time later Tony orders them into the bathroom; as they exit stage left, you can hear their disgusted reactions to the smell.
"Mom, I've gotta call you back. Something magical is happening!"
Towards the beginning, Happy haves difficulty using a tablet computer. Tony telling him to "flip the screen" (or rather turn the screen so the camera facing toward what he wants Tony to see) is the icing on the cake.
Tony has to hack the damn the thing just to see what Happy's fussing about.
Also, telling Tony about Killian. Obviously, he doesn't remember him.
For some Fridge Brilliance: JARVIS might well have been making a joke on purpose! Tony's clearly made him perfectly capable of snarking right back at him, and JARVIS getting back to that after being battered and broken (his voice sounding clearly distressed/faulty) is another good sign he's getting right back to how he should be.
Tony's reaction when he regains consciousness just in time to find out the suit's flown him to Tennessee:
Tony: WHY?! JARVIS: [incredulous, almost insulted] Because I made a flight plan!
Especially hilarious as Tony was in fact going to head that way before his home got blown sky high. He even ordered JARVIS to make a flight plan. So JARVIS's tone is "You told me to do it, dummy!"
JARVIS informing Tony he's made a safety protocol "for you to entirely ignore." Which Tony agrees he will.
Tony: Why are you wearing that hat? Because you earned it.
Savin going into Air Force 1 and killing the Secret Service? Disturbing. Savin repulsor-blasting one of them and then looking at his palm in a vaguely surprised "that was unexpected and yet awesome" way? Hilarious.
After Rhodey rescues Pres. Ellis and gets back in his armor, we get this exchange:
Rhodey: Ready, Mister President? Ellis: What do you mean, [Rhodey flies off suddenly while carrying the president] reaAHHHHHHHHHHHHHHH!
This exchange between Happy and Pepper early in the film, in regard to Happy wanting to replace the security staff with Tony's spare suits:
Happy: I'm just saying that the human element of human resources is a major weak point, we should begin phasing it out immediately. [beat] Pepper: What? Did you really just say that?
The Air Force One passengers who Tony save are credited as the "Barrel of Monkeys Skydiving Team".
Though it's a production gaffe, if you look closely during the scene where Tony threatens the Mandarin, the reporter's phone upgrades from a flip-phone to a smartphone merely by being in Tony Stark's presence.
The deleted scenes have plenty of it: extended takes for scenes here (the Tony fanboy, Robert Downey Jr. speaking plenty of one-liners before the repulsor glove arrives, Ben Kingsley doing various accents), turning the Newscaster Cameo from the beginning into full segments of Real Time with Bill Maher and Fashion Police, and Savin-dressed-as-Iron Patriot punching an NSA agent who annoys him.