Picture of Cardboard/Fiberglass Halo 3 inspired Master Chief Costume
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.

Step 1:

Picture of
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.
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Cookid1021 month ago
How much would you sell that costume?my gmail is chanceclarkekuzman@gmail.com
rickgyver (author)  Cookid1021 month ago
This is too near and dear to my son for me to sell. Plus it was custom made and would probably not fit anyone else correctly.

Hi! I am wanting to start this project for my son, but I need to know what pattern you used on pepekura.

rickgyver (author)  BritniH28 days ago

I didn't use a pattern. I referenced a couple of pictures from the internet and also the small plastic figure and just started cutting the cardboard. It was built on the fly, so to speak.

nrich21 year ago
Rick!!! You néed to email me so I can show you our master chief outfit! It's all with LEDs and your son would just love it! Uptheenergy@gmail.com
13, 2:00 AM.jpg

nrich2 how mutch for your costume led?

FyreHawk189 months ago
Are u gonna add instructions for the rest of the suit?
dark blade10 months ago

i love halo.it makes me so happy!I have the same action figure that you used to make the suit!

this has come in so handy!!!
it's also the armour i wanted too! :D
rickgyver (author)  Bwilson Props2 years ago
I'm glad to hear it. How about some pictures our your armor?
right here, my WIP Carter
Spartan 1.jpgSpartan 2.jpgSpartan 11.jpgSpartan 12.jpgSpartan 3.jpgSpartan 4.jpgSpartan 5.jpgSpartan 6.jpgSpartan 7.jpgSpartan 8.jpgSpartan 9.jpgSpartan 10.jpg
i've only managed to complete my weapons at the moment.
An MA5C Assault Rifle
A BR55 Battle Rifle
2013-07-30 17.02.34.jpg2013-07-30 17.02.45.jpg2013-07-30 16.56.58.jpg2013-07-30 16.56.21.jpg
nrich21 year ago
A company called: www.illuminautians.com
Has plenty of master chief outfits with LEDs all over! We love all of you so much for loving master chief. Check us out and email us with ideas, comments, and enjoy!
Dude thank you so much
I'm using a fiberglassing resin kit that cost AU.$ 30.00
What brand of bondo did you use?
Amazing Halo armor! Great work! May I ask you how much it cost to make the whole suit? I'm planning to make my own Halo 4 suit for Halloween.
rickgyver (author)  graphixcrafter2 years ago
It cost me about $150 USD for bondo, hot glue, paint, fiberglass, LEDs and misc. electrical supplies. The cardboard was from old boxes.
Amazing Halo armor! Great work! May I ask you how much it cost to make the whole suit? I'm planning to make my own Halo 4 suit for Halloween.
lordcooler2 years ago
i made a helmet using this design and it looked good
Pjnave1232 years ago
I'm 09 years old how much do you want for one of those master cheif suits in black.
csbrocket32 years ago
Nice instrutable!! :) Where do u get the fiber glass?
kschuster2 years ago
If you take commissions at all, id love if you made me a helmet. Give me a price :)
nerdcentral2 years ago
Nice! all i want is the helmet so its a great instructable for that. this is pretty much the best cardboard armour instructable iv found cause all i have is cardboard thx a ton
me too plz
ill post the helmant when it is done
MannyMTZ2 years ago
If i gave you the material would you make it for me? and if you can how much money do you want?
sparten 1172 years ago
hay i made the helment and just wont to no how do you make the chest pice
black hole3 years ago
It'd be cool to try to make N.O.V.A. 2 armor with this method. I would if I wasn't dirt poor.
koolkat66573 years ago
hi I’m in the process of making my own costume but having some trouble with codpiece, legs and arms. as fiberglass is relatively expensive I'm using paper mache to cover it. I've currently finished the helmet, chestplate and lower left arm piece. i'd also like to know how to make the halo scout helmet, chest plate, shotgun and should shields.
rickgyver (author)  koolkat66573 years ago
For the cod piece I just used a strip of cardboard to wrap around my son's waist. Then I added another one that went from the front, down through his crotch, and up the back. That gave me the basic sizing. The then added details. He wore a military style web belt and the cod piece had two velcro loops fastened to it, one on either side, that we tucked under the web belt and back up to attach to the other end to hold it in place. The web belt also had two loops of 1" wide web strapping that had plastic pinch-slide clips. They dangled down under the cod piece sides to hold the leg armor up.

The Chest plate was also pretty simple. I made a flat cardboard piece that was the correct shape and size, then added detail by cutting and folding cardboard to give it the 3-d shape. The shoulder shields were done the same way.

The scout helmet was built about the same way I made master chief's helmet. The gold face shield was a piece of a plastic laundry detergent bottle that I spray painted gold. There was a slit that I cut near the top so my son could see out of. You can kind of see in the pictures.

The shotgun was fashioned from a plastic toy m-16. I hacked it apart and used a length of 1" electrical conduit for the barrel. It was all hot-glued together and then I layered cardboard details on top.

Sorry I don't have any pictures of the scout or shotgun build.

Good luck.
THANKS for the tips!
koolkat66573 years ago
both of these costumes are so cool. FULLY AWESOME!!!!!!!!!!!
AustinL973 years ago
This is sooo sooo awesome.
zacli1234 years ago
Dude!!! that's amazing!!!!!!! Is it for sale???
rickgyver (author)  zacli1234 years ago
Thanks! No, my Son wants to keep it for when he has kids.
You do know Halo will never be forgotten right?
CostumeLord3 years ago
That is sick costume!
u r so right
skyrider943 years ago
AMAZing one question do you live in the usa
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