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I made a complete Halo 3 Master Chief Halloween costume for my Son out of cardboard and fiberglass. I started with the helmet. Here are the steps I followed. A small action figure and images found on the internet were used as patterns. The proportions and details may not meet the scrutiny of many 'super fans' but I'm sure my ten year old will like it just fine.
He has two Spartan weapons, a Sniper Rifle and an M6G Magnum
I have only detailed the build of the helmet here but you can see
the Complete Build here.
October 27th 2009 - I have just added pictures of the new helmet, chest plate, should shields and shotgun I built to modify the Master Chief costume from last year into a Halo Scout for this year.
He has two Spartan weapons, a Sniper Rifle and an M6G Magnum
I have only detailed the build of the helmet here but you can see
the Complete Build here.
October 27th 2009 - I have just added pictures of the new helmet, chest plate, should shields and shotgun I built to modify the Master Chief costume from last year into a Halo Scout for this year.
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I used thinner corrugated cardboard for the helmet. A bucket was made which was used as a base to build from. I measured from the top of my Son's head to the base of his skull where it meets the neck. I cut a 7" tall piece of cardboard and wrapped it around his head to get the right size and taped it to make an oval tube.
The first photo shows how I traced the outline on another piece and then drew about a 1" larger outline. I made sure both halves of the oval lid were symmetrical. I 'tabbed' the oval as seen in the second photo to fit inside the tube.
The last photo shows the flat piece hot glued to make the 'bucket'. Center lines drawn for reference.
The first photo shows how I traced the outline on another piece and then drew about a 1" larger outline. I made sure both halves of the oval lid were symmetrical. I 'tabbed' the oval as seen in the second photo to fit inside the tube.
The last photo shows the flat piece hot glued to make the 'bucket'. Center lines drawn for reference.
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LOL
Make your own Master Chief: www.squidoo.com/halo-armor-challenge
First, cut some strips of fiberglass cloth. If the piece you are covering is smaller and/or doesn't have a lot of curves, you can make the piece fit. Mix the resin and using 1" disposable paintbrushes (you can get a huge box from Harbor Freight Tools real cheap) paint a thin amount onto the cardboard where the cloth will be positioned. Carefully lay the cloth on and using the brush smooth it out. The resin should work its way through the cloth. You can add more to the top but do not load it on as it is hard to sand it back off. Carefully make sure there are no bubbles or wrinkles. Let the resin harden - depending on the temperature and humidity it may only be a couple of hours.
Work on small sections at a time as the resin will gum up within about 10 minutes. Do not mix too much at a time. You will figure out how much pretty quickly. If the area you are doing is flat and doesn't have many details, you can work a larger area with one larger mixing. If there are a lot of details, mix small and cut smaller fabric. Take your time to work edges and ridges. It takes some practice but it is worth the time.
Good luck.