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.
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.
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.
Step 2: Adding the Brim
Any time the cardboard needs to go around a bend, make sure to cut the cardboard so the corrugation ribs run perpendicular to the direcition of the bend. You can see this in the bucket in the first picture. The corrugation lines go up and down and the bend goes around. To make a smooth bend, you need to break down the corrugation. Do this by grabbing each end of the cardboard and running it back and forth along the edge of the table. See the last picture.
The second picture shows supports added to give the brim depth. The third is me tracing the outline to make the top of the brim and the fourth picture is one half of the brim completed.
Step 3: Rear Details Coming Together
Most of the original bucket will be cut away once there is enought support from the multiple layers of detail.
Step 4: Face Opening and Chin
Step 5: Helmet Top Primary Build
The back deck was installed and then a pattern of the shape of the notches in the top flat section was made. Pieces of cardboard were cut and bent along the sharp top angle and glued to the top.
Step 6: Helmet Top Decking
The decking was installed in several different pieces, each butted up and glued against the other.
The final picture shows some of the interior ribs that were added to hold the shape of the top.
Step 7: Modifications
Step 8: Chin and Cheeks
Step 9: Chin Detail
Step 10: Light Pods and Side Detail
Each time I measure and make a piece for one side I use it as a pattern for the other side.
Step 11: Brim Details
Step 12: Rear and Neck Detail
Now I'm onto building the body armor.
Step 13: Fiberglass and Bondo
When the fiberglass was cured I sanded it down and added several layers more of bondo, sanding each one in between.
Step 14: Painting
After letting the final coat of paint cure for a full 24 hours I weathered the helmet by spraying a small area with dark grey automobile primer and immediately wiping most of it off. Once this was dry, I dry brushed sliver paint to make the helmet look worn from years of battle.
Step 15: Face Shield
I fashioned a frame to attach the shield to out of cardboard and will hot glue to shield to the frame.
A few coats of gold paint to the inside gives it the look I wanted. I still need to add another layer to get the correct two layer style of the shield. Small slits will be cut into the shield where the two layers meet so my Son will be able to see.