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Does anyone have any tips for doing this right? Most of the time the default chaos lord used is one in terminator armor, but for my list I can only take power armor. The metal chaos lord in power armor available....well looks kinda silly and dated. I've tried looking but I've only found example of converted terminator lords. I'm doing iron warriors if that helps with any ideas. Also on a side note does the chaos lord still use the 25mm base if hes in power armor or does he use the bigger base that terminators use.

i think if he's in power armor he's able to use a 25mm base...
cant you use a techmarine as a base?

you will have a iron warrior warsmith in powerarmor with the servo harness as a base... some arm swaps, maybe a headswap... and your done

0.o Use the plastic kit and just convert it. I mean if you just add on some extra spikey bits he can be your lord, or you can sculpt on some details. My own lord uses bits out of the Chaos Marine and Space Wolves kits, amongst others. I made him about a head taller than my regular sudeo true scale marines, whilst giving him a prominent banner (warriors of chaos), and a big sword and shield. He can be mounted on a 25mm base, but his primary function is as a close combat unit, so personally (and for size issues) I mount him on a 40mm one. If your looking for ideas just google search Iron Warriors Warsmith on google or Dakka Dakka, there's loads of examples. =P

For iron warriors, I would use a tech marine a the base model and convert that. A head and shoulder swap, maybe the forge world character upgrade kit with bionic legs and hands.

For my iron warrior esque lord i started with the sergeant legs from the iron hands kit along with e metal pad with the hand filed off.
this is the only pic i have of him, taken with my dsi

Take a Techmarine, add some Chaos Head, a Twin linked bolter and then whatever else you need from a Chaos Sprue

lol seems people are not even reading the other posts since i already advised to use the techmarine