Cardboard/Fiberglass Halo 3 inspired Master Chief Costume

Step 2 Adding the brim

The brim was fashioned very similar to the bucket lid by drawing the pattern and tabbing the inside. I was very careful during the whole build to make sure all pieces were symmetrical. The brim was glued to the bucket at a slight upward angle as shown.

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.

Comments

[the dashing hero]

MAD CYBORG!

[grizzly010]

i sorda need more info how did u get the cuts

[supershot1]

i say spend 140 bucks and get the resin, fiberglass, cardstock, and pepakura designer

[PMBell]

cool costume one question though did u turn the top of the bucket in step one into the brim/cap thing or are they seprate peaces?

[mikey288]

I was amazed once I figured out it was made with cardboard. This is awesome!!!

[rickgyver]

Thanks! It was a lot of work but was definitely worth it.

[james v]

thats an awsome costume

[raff359]

you bet

[james v]

was it hard

[rickgyver]

It wasn't so much hard - it was more time consuming. I have a lot of experience with making costumes and other projects out of cardboard, but I guess if you are new to these types of things it might be tricky at first to get the proportions correct. Don't be afraid to try - it is only cardboard and you can always cut it apart and start over.