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.

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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

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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.
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noah1108 days ago
Is the armor hard enough to use in a paintball/airlift war? (Fiberglass armor)
Elkhoof1 year ago
KevinO1 Elkhoof5 months ago

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

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

LordJustice4 years ago
this may seem stupid, but how am i gonna print on the cardstock?
i need the answer too.

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

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

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

clinville210 months ago
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

Could you make me a suit of armor?

keshiro4 years ago
how do you scale the armor in pepakura?

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.

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
tell me, do you get a monthly bill or somthing
like that in the desighner vesion?
or do you just pay to download?
you just pay for an activation key.
paddy1231 year ago
mine came with no flaps to help hold it togeather
Epic 8 mm 1 year ago
Oh BFX... May you rest in peace :(
Menkui1 year ago
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.
spart111 year ago
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
Have you thought about making armore out of titaiam solafyed to the point that it is highly bullet proof and bulet proof glass bult in a stile that takes in light in the dark, resist light when its bright, and bult in a nassa worthy radeation proof stile? Titaneum actuly is not a rare mettle at all, but its like trying to tame a fearsome roge deadly beast trying to make somthing out of it. Titanum is radeation proof, resist electrisaty, is 10 times lighter waight then alunanam, and can be stronger then steel. It even resist agenced heat and cold.
First, metals DO conduct electricity, and titanium IS a metal. Second, it is denser and heavier than aluminum. Check a periodic table. Also, this thing called spell check came around a few years ago. All those annoying red lines under your words, yeah, those are saying you need English lessons. Next, that visor you mentioned, there's a word for that. Transition lenses, they polarize in sunlight. Taking in light makes no sense. Try infrared night vision. Expensive. By the way, it's NASA, and their space suits aren't made of titanium. Also, why "rogue fearsome deadly beast"? Have you worked with titanium? All the molding and melting and cooling and hardening that would have to go into that; if you aren't rich, you are not doing that. Also, metals have this tendency to amplify heat and cold. Throw a can in the sun light in summer or snow in winter, and it will get hot or cold respectively. Highly solidified titanium may be bullet proof for a time, but it's not dent proof, and buffing out dents in solid metals is NOT easy. Lesson to be taken: read up before posting ideas. Some things just won't work. And again, try spell check next time.
(be shure to post pics though.)
sorry, but im not sure if I trust your spelling. again, sorry
that would be................
sounds expensive though........
started my suit about 4 months ago... looks legit so far. will send pics as soon as possible
ranndoo1 year ago
Also, can anyone explain how to scale the default pepakura file sizes smaller?
ranndoo1 year ago
How long did this take you?
adougherty12 years ago
it wont let me get blueprints of armor without having to buy some stupid software ccan someone help me out
I was thinking of putting a few layers of kevlar fabric on the inside so it protects but tellme if its a had idea
Dumchicken4 years ago
can you make halo armor?
I can make Halo armor, I did an instructable and you can find materials and tutorial videos here:
Drop me a message if you need help or need me to make you specific parts
Hey how much would you make the whole armour for and then post it? It's just I am not very good at following instruction or building things. Thanks
My price for a custom Mark VI, painted and padded as you see in the picture is $3300 plus shipping. Shotgun is an extra $300.
hey master chief isnt that a bit expensive. anyways is there anyway you could make a suit for a 14 year old for about £1000
howed you make the gun
I used layered foam with reinforcement rods sandwiched inside.
Here is a link to a progress thread I wrote on the 405th:

And it is up for auction, here is the link:
Here is our Halo 3 shotgun version 2. As you can see it is even more game accurate and also, the sights light up. To see how it was made and/or make your own visit:
wow so cool i love the shot gun hey in a private message if you want to we can be xbox live freinds mine is gavinxyz
JESUS!!!! That's is well expensive! Sorry but I wont be purchasing the whole thing, how much for the helmet??
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