V.W.
3 gifts
Iron Man goes to your youngest.
Hulk to the oldest.
The other two wrapped together with both boys' names on them.
They will share them all anyway, right? My kids have pretty much always been expected to share with their toys, even when it "belongs" to them exclusively. It has never been a problem. And since that is the expectation your boys have always had regarding costumes, it shouldn't be an issue with them either.
ETA:
We do this all the time. In fact, I just finished wrapping an old fashioned popcorn popper and put both the kids' names on it. They will love it. Any video games (not handhelds, but like PS3, Wii, etc) all those things are family or joint gifts. And usually there is an actual game of some sort (board games or whatever) and those are joint or family gifts. I grew up with stuff like this. I didn't know other people didn't. hmmm learn something new every day. :)