Introduction: Build Halo Armor

This week on [http://www,indymogul.com/bfx Backyard FX] we show you how to make a futuristic set of space armor just like Master Chief wears in Halo 3.


Step 1: Shopping List

- Ream of Heavyweight Card Stock
- 2 Aqua Resin Starter Kits
- 2 yds. Fiberglass Mat
- Nylon Straps and Buckles
- 4 ft. of Velcro
- A few feet of 1 in. Foam Padding
- Cheap Black Gloves
- Dark Colored Under clothes

Step 2: Get Blueprints From These Sites

Step one is go to this link: http://www.indymogul.com/3RR and download the free Pepakura viewer. It lets view and print out the blue prints directly on to your cardstock. There is a ton of information and pepakura blue prints at 405th.com, and or just type in this shortcut http://www.indymogul.com/3RS to see my guide to get you started.

Step 3: Cut and Fold

Now you can start the cutting, folding and gluing process. Its sort of like origami on a bigger scale.

Step 4: Waterproof the Cardstock

Once you have a complete section of the armor folded and glued you need to waterproof the cardstock with a clear coat. THEN cover the inside and outside with some aqua resin. Aqua Resin is like polyurathen resin but way less toxic and less stupid about curing temperatures.

So one glazing coat of aqua resin on the inside of the carstock form and one on the outside.

Do these one at a time, each coat should take about an hour to cure.

Step 5: Apply Fiberglass

Next you’ll need to add apply one or two layers of fiberglass for added reinforcement. These layers
go on the inside only and use fiberglass veil and some more of your aqua resin! This should take
at least 2 hours to cure.

Step 6: Carve Out the Details

Now that your armor is sturdy you can get in there with a rotary tool and carve out some details. Some bondo or plumbers epoxy can help here but only if you have some extra cash.

Step 7: Paint the Armor

Now we need to paint and distress the armor. My armor is 1 coats of primer, 1 of silver and 1 of flat black.

Step 8: Straps and Padding

So the last steps are padding and strapping. Probably the most frustrating part of the build. Youll need to glue in padding and attach nylon straps until all the armor sits right on your body. That is the basics of building armor.

And for the helmet you can totally use this technique just add a cheap motorcycle visor and add some if your feeling crazy add some light!

Step 9: Warnings and Common MIstakes

Also here are the 5 most common mistakes people make when building their first armor.

1) Not being patient. It can take as long as a year to build one suit
2)Don't fiberglass the outside of the armor, and when applying your veil use small chunks, not big ones.
3)Don't forget to scale the armor to your body. The real master chief you are not.
4)Don't forget the under armor. It can be as simple as dark colored long johns, or as expensive as fancy pressure suits.
5)Not reading the safety instructions. Dust masks and eye protection a must.

Comments

author
TheParrot made it!(author)2012-04-02

Um, I know this is probably the wrong place, but I would love to apply these building techniques to some Mass Effect N7 armor, but I can't find any papercraft pepakura templates anywhere, and I've looked EVERYWHERE. I've seen plenty for helmets, but I would love it if there were some armor templates out there. I like the carbon-fiber appearance of the EVA foam armor, but I just don't like the idea of constructing an entire suit of armor out of it, even if it is ballistic foam.

I mean, some pieces would have to be constructed out of EVA foam for flexibility, especially the jointed spinal and abdominal pieces, but I think that resin armor would be so much more durable and better-looking than armor made entirely of EVA foam.

I do plan on getting into Halo, as yesterday I was struck with a very strong desire to play the games, which I do not have... and I would love to build my own set of Spartan armor as well as N7 armor.

Any help with N7 pepakura armor templates would be greatly appreciated. Thank you!

-Parrot

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Psiborg made it!(author)2017-03-29

www.therpf.com/showthread.php?t=186674

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Dinoman217 made it!(author)2016-01-28

This is awesome! Just one question, where do you get aqua-resin from?

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MatthewN32 made it!(author)2016-04-14

you can get it at al local home depot, menards, or hardware store.

hope this helps.

author
MatthewN32 made it!(author)2016-04-14

this looks like a great build, yeah it may take a while to make and the fiberglass is a tad itchy, but it looks pretty worthy of trying, Thanks!

author
nerd12 made it!(author)2011-07-01

pls tell me how hard is fiberglass mat because when i make it it will spoil the effect if it bends when its pressed. is is possible that it can be made with out the paper because i was thinking of making each piece separate. as in the forearm will have 2 pieces opposite each other. i was thinking of making this out multiple layers of ply wood laminated together into a curved piece so that it would stay together and curved. thanks :-)

author
jmanukonga made it!(author)2016-02-04

duude, making it out of ply would be one pain in the rear kind of job... I wouldn't take that up if I were you

author
Jandro made it!(author)2011-06-17

Can the pepakura file be converted to work in blender?

author
jmanukonga made it!(author)2016-02-04

that's a good question, it probably could, but at the same time, why would you want that? for easier editing or for animating?

author
eatchyboy427 made it!(author)2015-12-14

Absolutely amazing! If you wanted to do it properly though, put graphene on it!

author
ChristopherB51 made it!(author)2015-11-17

I'm thinking about giving this a try in a few months when I have room in my garage and time. I would like to pay someone to do it for me though if the price was reasonable. I can paint it and do the padding, I just need the armor itself made and the helmet. I can do the rest like add detail etc.

Some things may be difficult for me like making a god helmet and boots. I want the boots to have some heft to them so when I walk it sounds like I'm a Spartan. maybe use some rollerblades without the wheels and paint them plus add some pieces to it.

Another idea would be to get some thin sheet metal and cut it to lay over the armor and maybe attaché with rivets and an epoxy then paint over it. Not the entire suite but over some of the flat sections on the chest and arms and legs.

Maybe on the back a small fan running off a tablet sized battery could be used for cooling.

Anyways, some ideas. As for making it a more functional suit. Kevlar paneling might help but to really hold up against impact you would need a composite that's light weight but strong like carbon fiber but even that's heavy and will only take a few blows from a determined attacker.

What makes the Halo suit in the game more plausible is the gel stuff between the body and the armor that locks up and protects the wearer. Its circulates temperature and keeps a seal from the outside atmosphere. Also being huge and full of muscles to help carry that suit is what does it.

So I would focus more on a well detailed and well built suit for show not for use. You can get away with paintball but you will sweat you ars off and probably get it broken after a couple games.

author
trevor.estelle made it!(author)2014-08-10

What is a decent alternative to Aqua Resin? I can't find it anywhere.

author
turtleturtle made it!(author)2015-10-10

Fiberglass

author
ray.gutierrez.921 made it!(author)2015-04-07

I know this a stupid question but how do you Waterproof the paper?

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turtleturtle made it!(author)2015-10-10

Fiberglass resin if paper clear coat* I think if foam

author
DehLeprechaun made it!(author)2015-07-29

Clear Coat, its like spray paint. At least that's what it looks like the instructions say.

author
LintBallz made it!(author)2015-05-29

It's not a stupid question. I don't know the answer, but I do know that the only stupid question is the question not asked. Questions mean you seek knowlage. Also the answer might be Neverwet. It's a waterproof spray that works on almost anything.

author
rmayall1 made it!(author)2015-08-26

would it be possible to make the armor pieces carbon fibre instead? and use the paper models as molds?

author
noah110 made it!(author)2015-03-20

Is the armor hard enough to use in a paintball/airlift war? (Fiberglass armor)

author
BenjaminW10 made it!(author)2015-06-17

First, I want to make it clear that I am only familiar with paintball. Second, I'm pretty sure that paintball is more restrictive than airsoft in terms of protection.

Ok, so a friend and i have been researching this project for almost two years off and on for the explicit purpose of paintball. In scenario ball, this armor is allowed. When building your helmet, take a certified face mask (helmet might be too hot and too heavy, so I don't reccomend that), to use as a baselayer. We are taking a single lens helmet so that we can add a custom double visor along with a comms unit display (programmed by an arduino using c) as well as some other nifty tricks. Remember that in actual use, mobility is key. The spartan suits had 97% mobility with 93% coverage if I'm not mistaken, but that's extremely hard to do on the civilian side.

Woodsball is slightly more restricted than scenario. You would have to check your competition guidelines. As for speedball, I personally have no interest in it, therefore I can't give any assistance on that. Hope this helps!

author
Epic+8+mm+ made it!(author)2013-11-02

Oh BFX... May you rest in peace :(

author
LintBallz made it!(author)2015-05-29

Actually, Zach, (That's his name right?) isn't all that bad. He's different, I know, but come on guys, that change was so long ago...

author
AlanaP1 made it!(author)2015-05-11

My only confusion is the clear coat before the aqua resin. Does it come in the kit or what is called/what do I use?

author
Elkhoof made it!(author)2013-12-10

WHERE IN THE HELL ARE THE BLUEPRINTS FOR THE ARMOUR MOLDS!!! PLEASE SOME ONE GIVE ME A LINK OR SOMETHING!!!

author
KevinO1 made it!(author)2014-10-08

i get mine on 405th.com they have all the blue prints you need and you will need pepakura download

author
Sir+Fluffulus made it!(author)2014-03-25

All the files I've used are on 4shared.com. You can find the links on 405th.com, but I found it easier to use http://halocostuming.wikia.com/wiki/Pepakura_File_...
Halo Costuming has most, if not all the files you'd want, unless you want Halo 4 armor, then you'll want http://www.4shared.com/folder/WjJPWspL/Mk_online.h... which is all the current Halo 4 Master Chief files.

Hope this helps

author
LordJustice made it!(author)2010-10-04

this may seem stupid, but how am i gonna print on the cardstock?

author
machomike22 made it!(author)2010-10-11

i need the answer too.

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essie91 made it!(author)2014-09-02

go into your printer settings and change the thickness of the paper

author
Bennions89 made it!(author)2010-10-11

uh you put it in the paper try or your printer, turn on your printer and press print on your computer

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clinville2 made it!(author)2014-05-15

I'm in the army and don't have time to make one or the space but if anyone can make me one I will pay them

author
Imfamous_idavis made it!(author)2014-05-10

Could you make me a suit of armor?

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keshiro made it!(author)2010-12-01

how do you scale the armor in pepakura?

author
Sir+Fluffulus made it!(author)2014-03-25

When printing, next to the printer name is a tab called "Properties." When clicked, go to the tab "Advanced" and then the picture that is the large A to the small A. Click on the "Free [25-100%]" and then scale as necessary.

If you're asking about Master Chief size to your size, it just happened to work when I took Chief's size in inches, assuming 7 feet would be 84, and then my height in inches, which is 72 inches, and found what percentage it would become, example, my 72 over Chief's 84, then multiplied by 100 which is 85.7. With this number, I scaled the file to 86% size, and it worked wonderfully for every body piece.

author
mistdemon123 made it!(author)2011-09-19

you need the pepakura designer. you can download a trial version free, but some features are disabled. otherwise, it can't be scaled. you need desinger, not viewer

author
hrodriguez7 made it!(author)2011-09-23

tell me, do you get a monthly bill or somthing
like that in the desighner vesion?
or do you just pay to download?

author
ghostrider2 made it!(author)2011-12-02

you just pay for an activation key.

author
paddy123 made it!(author)2013-12-08

mine came with no flaps to help hold it togeather

author
Menkui made it!(author)2013-09-24

I have a few questions, first, how thick does the armor plates end up being?
Seccondly, how tough is it? - I mean, would it hold if someone took a swing at you?
My reasons for asking is that my boss wants to make a warhammer 40.000 Grey knight armor for... I dont really know, some event I guess. And if its tough enough, maybe make a larp monster suit.
-So yea, it doesnt have to withstand a nailed baseball bat, but alot of kids swinging larp weapons at it.
- Thanks in advance.

author
spart11 made it!(author)2013-09-24

i might try it idk tell me how it works please and if ur talking to me just say artemis please then say ur answer i wont be very active

author
grimthastheflatulant made it!(author)2013-07-25

started my suit about 4 months ago... looks legit so far. will send pics as soon as possible

author
ranndoo made it!(author)2013-07-03

Also, can anyone explain how to scale the default pepakura file sizes smaller?

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ranndoo made it!(author)2013-07-03

How long did this take you?

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adougherty1 made it!(author)2012-12-12

it wont let me get blueprints of armor without having to buy some stupid software ccan someone help me out

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derpjustastraightupderp made it!(author)2012-11-09

I was thinking of putting a few layers of kevlar fabric on the inside so it protects but tellme if its a had idea

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dezeldamaster made it!(author)2012-10-23

I have a question. The links in the video does't work for me. Can someone help? Thanks

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WerewolfCas made it!(author)2012-10-27

The IndyMogul website doesn't exist any more. But you can go here for the paper craft. http://halocostuming.wikia.com/wiki/Main_Page Hope this helps.

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Vatterix made it!(author)2010-11-08

hey is there any way to make this paintball proof? if anyone can give suggestions I am more than willing. I own a field so we are planning on spicing it up a bit with these aaaand I think you can understand I dont want to do repair all the time

author
evilmadcow made it!(author)2012-09-01

is'int Fiberglas paintball prof enough?

author
tinker234 made it!(author)2011-07-18

well it would be simple to add a layer of sheet metal to it then sprray paint it your color

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Bio: Indy Mogul is the network dedicated to DIY filmmakers and film lovers alike. Our first show, Backyard FX, is a creative and funny 'how-to' guide ... More »
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