Master Chief Halo Armor.

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Introduction: Master Chief Halo Armor.

This indestructable is on making halo armor.

MATERIALS:

Lots of cardstock
glue and staples
lots of pading black is probably the best color
motorcycle visor
reference pics
dobble sided tape
LEDs optional
primer, spray paint
velcro
computer
printer
fiber glass mat 3 yards
lots of straps

Step 1: 1 Getting Started

Go to this link and download Pepakura you will need it to print the armor layout.
http://www.tamasoft.co.jp/pepakura-en/

Then go to this link to chose what parts and weapons you want.
http://halocostuming.wikia.com/wiki/Pepakura_File_Index

THIS IS IMPORTANT
On Desktop make a separate folder named Halo Armor
When saving the files be sure to save then to the Halo Armor folder and BE SURE TO RENAME THE FILES TO WHAT PART OF ARMOR THEY ARE...... TRUST ME

Also go to this link to chose reference pics. Print at least 10 on 2-3 pieces of paper.
http://images.google.com/images?hl=en&q=master+chief&gbv=2&aq=0&oq=mast

http://images.google.com/images?gbv=2&hl=en&sa=1&q=halo+armor&btnG=Search+Images&aq=0&oq=halo+ar

The first link has better pictures. Heres more links for reference pics.

http://photobucket.com/images/halo%20armor/

http://picasaweb.google.com/lh/view?q=halo%20armor&psc=G&filter=1#

Step 2: 2 Basics

Print the layout on card stock or heavy paper.
If you use heavy paper you might need to feed it into the printer one at a time.
BUY A BIG PACKAGE OF PAPER EACH PART OF ARMOR IS AT LEAST 7 PIECES OF PAPER .

Step 3: 3 Hardest Step

After printing cut out all the pieces with scissors or a utility knife.
Fold and assemble all the parts. Use glue and small staples if you are sure they will be invisible when the armor is complete.
This is probably the step you are going to take the most time on.

This is the result of how your armor/weapons should look right now.

Step 4: 4 Biggest Step

Get 2-3 buckets of aqua resin.
Apply one coat on the inside of the armor and give it at least an hour to dry.
Repeat with the outside.

You can carve out detail with a rotary tool they cost $15 at big art supply stores.

Now is the time to paint your armor. USE SPRAY PAINT The best color combination is
1. Primer
2.One coat of silver.
3.One coat of desired color. (Black works best)

Since your armor isnt very strong break up the fiberglass into small pieces. The pieces should not be any bigger than a.................. cracker or half the size of your cellphone screen (unless you have an iPhone, then go with 1/3)
Glue in the pieces of fiberglass ONLY ON THE INSIDE , REALLY .......... YOU WILL MESS IT UP TRYING TO PUT IT ON THE OUTSIDE.
After gluing in the fiberglass, put more glue on top and put in the foam (not Styrofoam) it should all ready be cut to size.
NOT ALL of the inside should be covered just in the center.
KEEP foam at least 1-2in away from the edge of your armor if you don't it will stick out and look ugly.
The foam should be about 1in thick.

Step 5: 5 Helmet

After completing all the steps will notice that the helmet is not functional. To solve this problem cut out the visor. Carefully replace it with the motorcycle visor. You can find one on eBay or at a junk yard.

Step 6: 5 Straping In

Now to make your armor wearable you need to find some log johns just like the ones it the picture.
Get black colored ones since they look like realistic under-armor.
HERES A VERY IMPORTANT TIP: GET LONG JOHNS THAT ARE 2 SIZES BIGGER THAN YOU SO YOU CAN WEAR YOUR ARMOR OVER CLOTHING.

You will need a friend to help you in this step.
Put on your long johns. Start with the chest piece and work your way down.
When putting on your armor be sure to strap it in tightly.
A good idea is to use plastic buckles (picture bellow) but only if you can hide them under the armor.
After putting on a piece of armor move around to be sure its comfortable.
This step may take a while, but if you don't take your tine you will regret it latter.

Step 7: 6 Final Step

Make weapons the same way but without the foam.

contact me at:
coolgameweasel@aim.com or visit my myspace at myspace.com/weaselonferrari

HAPPY BUILDING

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40 Comments

I made one master chief rules

Do you put the fiberglass on the inside before or after painting?
How thick should the fiberglass be?
Thanks in advance

1. Doesn't matter

2. I recommend about half an inch but if the armor is to big for you probably all the way until it's comfortable and fits you

3. Np

about making weapons how am i suppose to put resin and cloth on the inside of a weapon from halo?

most of them are modular, so you can do one piece at a time. the assault rifle, for instance, is broken into about 30 different pieces that go together once assembled

Far easier and less time consuming to make this armor out of foam floor mats! I have an instructable up and this page has materials for sale and tutorial videos -> www.squidoo.com/how-to-make-halo-armor

I am needing a skilled armor maker to fabricate a master chief costume for my 7 year old son. Nothing super fancy. just something that he can wear for halloween. Something that Velcros on. It can be bule colored or green. He will wear black under armor. I would like to have him a head piece but it can not cover the face (school rules). I will pay 300-400 $ to have this project completed.

Email me at rjbthor@yahoo.com asap if you are willing.

you can buy them off of eBay for $300.