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#freeironmanplots "Blast From The Past #1". The IRL Meat version of Tony is offline and an AI imposter takes over. So I've read some of the stories where Tony makes an AI out of himself, and each time he builds an AI it seems like a very chaotic process - hold that thought.

Tony in a fight gets clobbered, and takes some traumatic injuries. He sinks to the bottom of the sea (or someplace). His suit thankfully is mostly OK, but damaged. Internal repair stuff is busy fixing it. However Tony is in a coma, suit is stuck (with plenty of power.) Meanwhile!

Some protocol goes off and it sticks a Tony AI in a spare suit of armor to go find Tony and provide assistance. And maybe he does and the down suit says "actually, we're good - we'd rather repair where his enemies can't get him. You be Tony until the repairs (medical/scientific) are done."

So basically the AI masquerades as Tony for a real long time. Trying to keep it secret. Trying to explain why no body in the suit. For real serious hijinks, maybe the protocol stuck multiple version of Tony over the years so a group of AI can run things in the hope that they'll police each other.