Introduction: Build Halo Armor

Picture of Build Halo Armor
This week on [http://www, 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

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- 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

Picture of Get Blueprints From These Sites

Step one is go to this link: 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, and or just type in this shortcut to see my guide to get you started.

Step 3: Cut and Fold

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

Step 4: Waterproof the Cardstock

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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

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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

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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

Picture of 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.


ky.morrison (author)2017-10-05

can i buy one for a good price

ky.morrison (author)2017-10-05

how expensive is it and can a 10 year old make it.

TheParrot (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!


Psiborg (author)TheParrot2017-03-29

Dinoman217 (author)2016-01-28

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

MatthewN32 (author)Dinoman2172016-04-14

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

hope this helps.

MatthewN32 (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!

nerd12 (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 :-)

jmanukonga (author)nerd122016-02-04

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

Jandro (author)2011-06-17

Can the pepakura file be converted to work in blender?

jmanukonga (author)Jandro2016-02-04

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

eatchyboy427 (author)2015-12-14

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

ChristopherB51 (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.

trevor.estelle (author)2014-08-10

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


ray.gutierrez.921 (author)2015-04-07

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

Fiberglass resin if paper clear coat* I think if foam

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

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.

rmayall1 (author)2015-08-26

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

noah110 (author)2015-03-20

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

BenjaminW10 (author)noah1102015-06-17

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!

Epic 8 mm (author)2013-11-02

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

LintBallz (author)Epic 8 mm 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...

AlanaP1 (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?

Elkhoof (author)2013-12-10


KevinO1 (author)Elkhoof2014-10-08

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

Sir Fluffulus (author)Elkhoof2014-03-25

All the files I've used are on You can find the links on, but I found it easier to use
Halo Costuming has most, if not all the files you'd want, unless you want Halo 4 armor, then you'll want which is all the current Halo 4 Master Chief files.

Hope this helps

LordJustice (author)2010-10-04

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

machomike22 (author)LordJustice2010-10-11

i need the answer too.

essie91 (author)machomike222014-09-02

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

Bennions89 (author)machomike222010-10-11

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

clinville2 (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

Imfamous_idavis (author)2014-05-10

Could you make me a suit of armor?

keshiro (author)2010-12-01

how do you scale the armor in pepakura?

Sir Fluffulus (author)keshiro2014-03-25

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.

mistdemon123 (author)keshiro2011-09-19

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

hrodriguez7 (author)mistdemon1232011-09-23

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

ghostrider2 (author)hrodriguez72011-12-02

you just pay for an activation key.

paddy123 (author)2013-12-08

mine came with no flaps to help hold it togeather

Menkui (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.

spart11 (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

grimthastheflatulant (author)2013-07-25

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

ranndoo (author)2013-07-03

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

ranndoo (author)2013-07-03

How long did this take you?

adougherty1 (author)2012-12-12

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

derpjustastraightupderp (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

dezeldamaster (author)2012-10-23

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

The IndyMogul website doesn't exist any more. But you can go here for the paper craft. Hope this helps.

Vatterix (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

About This Instructable




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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