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Cardboard/Fiberglass Halo 3 inspired Master Chief Costume

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.

 
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Step 1

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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356 comments
1-40 of 356next »
Apr 16, 2012. 6:21 PMAustinL97 says:
This is sooo sooo awesome.
Sep 28, 2010. 12:18 AMzacli123 says:
Dude!!! that's amazing!!!!!!! Is it for sale???
Mar 18, 2012. 2:47 PMdamastacheef says:
why? halo will be forgotten in that time.they might say it sucks.
Apr 1, 2012. 6:31 AMbillyjoeface says:
You do know Halo will never be forgotten right?
Mar 21, 2012. 4:08 PMCostumeLord says:
That is sick costume!
Mar 27, 2012. 4:23 PMdm.199 says:
u r so right
Mar 27, 2012. 4:22 PMdm.199 says:
tgfuyfruerhughrtghrthgiohgbuirthighirtghurgvufgurgrugyfdcfgydftsfggysdffyfsfyfsdysdfydffysdffyfdyfysdfysdfyfffyfyfsdyfydfydfdfysfyfdfyfsdyfsydfsddtfdsdfghgghghggghghghghggygygygyggyygygygyygygyhyygydcsfffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffffftyfdtfdydgugfusdfgusgusfdgfygfugfugfugfufgufsgufsgsfugfufgu
Feb 1, 2012. 4:48 PMthe dashing hero says:
i was killing grunts and a grunt said "mad cyborg!"
LOL
Mar 18, 2012. 2:40 PMdamastacheef says:
aye?

Feb 13, 2012. 1:12 PMthe dashing hero says:
dude (first pic) is that a sniper? i have the anaversery and i sniped a elites balls...... he held his balls and died
Mar 18, 2012. 2:38 PMdamastacheef says:
man that is awesome! but saddly i cannot do it on combat evolved:'''(............
Mar 4, 2012. 2:24 PMcleage001 says:
Could I make a juggernaut (MW3) armor using this method?
Feb 1, 2012. 4:50 PMthe dashing hero says:
MAD CYBORG!
Feb 1, 2012. 4:49 PMthe dashing hero says:
MAD CYBORG!
Feb 1, 2012. 4:49 PMthe dashing hero says:
MAD CYBORG!
Feb 1, 2012. 4:48 PMthe dashing hero says:
MAD CYBORG!
Oct 28, 2011. 11:44 AMkanalav says:
My brother says "awesome" and asks how long it took to make.
Oct 30, 2011. 6:13 PMeatmeidareyou says:
omg i want that
Oct 8, 2011. 9:31 AMskyrider94 says:
AMAZing one question do you live in the usa
Oct 9, 2011. 2:36 AMskyrider94 says:
:( i was gonna buy off you but you live to far away GREAT COSTUME ANYWAY
Mar 18, 2012. 2:42 PMdamastacheef says:
you live were? im not a criminal i promiss. i wanna buy it!
Mar 18, 2012. 2:32 PMdamastacheef says:
how do u do da part dat looks like underware?
Oct 6, 2011. 1:28 PMmtsabrova says:
oh my god! i'm making this thing for next year!
Sep 25, 2011. 12:09 PMronkey says:
Awesomen best one I've seen!!
Aug 8, 2011. 1:37 AMJorge Ivan says:
best halo costume on all INSTRUCTABLES.com
Aug 4, 2011. 10:27 AMVerttech4 says:
I like this alot :D
Jul 29, 2011. 10:33 AMbbrown16 says:
this really locks like a halo 3 master chief helmet.
Jul 27, 2011. 11:44 PMkkohl2 says:
this looks wayy nice, I don't believe it's made of cardboard xD
Jul 22, 2011. 2:01 PMevilmadcow says:
if you have a heat gun you can make it out of utility foam.
Jul 16, 2011. 10:39 AMtinker234 says:
hey there are sunglass with master cheif tint could i use those for the eye holes
Jun 24, 2011. 12:20 PMSteampunkManiac says:
MASTAH CHIEF!! WOO! WOO!
Jun 2, 2011. 2:47 AMgrizzly010 says:
i sorda need more info how did u get the cuts
May 11, 2011. 3:29 PMender23 says:
DUDE! REALLY HOW DID YOU MAKE THOSE BOOTS!
May 11, 2011. 2:39 PMender23 says:
DUDE! Awesome! but I noticed on the complete build you highlighted that you didn't have the pictures or instructions on the m6g magnum or the gloves and boots. Do you think you could add that and add some instructions to the; chest plat, arms and legs, guns, lighting, and gloves and boots. PLEEEEAAAASE MAN PLEASE I'm making this for the comic conn this year and I really want to make it.
May 5, 2011. 10:53 AMPlo Koon says:
THAT IS SUPER-DUPER MEGA ULTRA UBER UNNECESSARILY AND COMPLETELY AWESOOOOOOOOOOOOOOOOMMME!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
May 4, 2011. 11:28 AMgoldneye00 says:
I added my own liitle touches to the magnum and made myself a rocket launcher that clips to the back of the suit.....
May 4, 2011. 12:11 AMhalo 3 says:
That is so so so good im going to make that master chief costume and i just printed the instructions out to make it.
1-40 of 356next »

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