Introduction: Halo Reach Mark V Armor

Picture of Halo Reach Mark V Armor

This is a brief description on how to make a costume from EVA foam tiles. Hopefully my pictures will provide good reference on how to solve pesky parts or how to achieve a certain look. This is my suit create last year from foam. Well, here's just an extremely brief tutorial on how to make your own armor, costume, or anything else you can think of from simply foam tiles, misc parts, and glue. Due to the extreme time frame and difficulty of such a project, this is a very brief description of how to.
1.) Using templates from online or models of your own, trace the parts onto EVA foam tiles.
2.) Cut them out using either an exact o blade or a snap-off carpenter's blade.
3.) Assemble the pieces using a glue gun, being careful not to use too much!
4.) Cover the finished pieces with a coating of Plasti-Dip spray and paint.
5.) Add any other details such as lights and decals.
That is the most basic of ways to create a set of armor from these foam tiles. 
The Helmet was made from a pepakura model hardened and smoothed with Bondo and resin.
The entire suit was later airbrushed with simple black paint on the edges.
The rifle is partially a modified nerf gun with a wooden lower receiver, stock, butt, and "mag" The ammo counter assembly and barrel assembly are styrene and other misc household things. 
-50+ Foam Tiles
-100+ Various screws for details
-15+  Cans of spray plasti-dip and paint
-150+ Glue gun sticks
-10 ft of blue EL wire
This complete costume would have to be broken down into numerous step by step tutorials to be complete, but I would like this up here for some constructive criticism for suits to come!


Blu dude 2004 (author)2016-12-04

quick question do you even need the costume?.....I mean sure you put a lot of work into it.but I'm really vulnerable

for a costume and I'm running out of time so....can I take it out of your hands?

blackholeseeker (author)2015-10-30

Not to let my halo geekiness out on this instructable, but that armor is grenadier armor, ONLY in halo Reach.

Actually its Grenadier Variants...Jorge's armor

blackholeseeker (author)2015-10-30

Can you make a noble 6 build next?

TreeHobo7 (author)2015-04-25

how/where did you get/make the the gun?

gunman15 (author)2015-03-08

Now I shall use this method for my red vs blue Tex Cosplay for Youmacon! THANK YOU SO MUCH!

margery.lovett (author)2015-01-17

Saw this on Pinterest. It is artistry! Amazing.

MoFracka (author)2014-11-27

thats amazing!!!

ffrench (author)2014-11-26

How did you make the assault rifle to go with the armour?

DaGoldenGunner (author)2014-08-20

What do you use for an underskin?

KenSFX (author)2014-07-21

Excellent work! Even though I am a fan of GEARS OF WAR, this is also an Xbox favourite. I look forward to more of your projects!

nwalker13 (author)2013-11-05

The gun is amazing!!

jmodine (author)2013-10-30

How did you make the arm pad that holds the phone

SlyProphet (author)2013-10-13

What was the material you used on the visor? And how well can you see through it?

popebawbag (author)2013-08-23

How many do this do you have?

Duct-Tape-Master (author)2013-08-20

what did u use for the visor?

chrismist (author)2013-07-17


The Irish Cowboy (author)2013-03-10

My full length tutorial is located here--> :D

Gregbot (author)2013-03-10


ccobra (author)2013-03-09

dude that is soo cool I might make my own, but it probably wont be as good as yours
:) ^_^ :)

budhaztm (author)2012-12-17

Two Words: Epicness Maximum

SunderOrigami (author)2012-11-24

Wow, I'm impressed! It looks amazing.

poofrabbit (author)2012-11-13

Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!

Paulbacca (author)2012-10-24

Very cool! If only I had the time to make it.

tlingbeck-1 (author)2012-10-21

I love this!!!! When will you post a step by step if you decide to do so? I love the idea of putting a smart phone in the right arm :) i saw the verizon emblem lol. that is such a great idea!

Thanks! I'm glad you like it! I will have my MassEffect suit done by March, so I will most likely have a step by step up in the winter!

o__o (author)2012-10-15

The best Halo suit I have seen! Wonderful job! Thinking of making Emile?

The Irish Cowboy (author)o__o2012-10-16

Thanks! But, no.....i'm waiting for Halo 4 for my next suit ;)

wolfman2152 (author)2012-10-07

awesome suit, just incredible. i am trying to make a much less complicated one for halloween, and was wondering what nerf gun you used. once again, amazing.

Thanks! The nerf gun i used was the nerf recon, its fairly mod-able. The front half of mine slides off to reveal the wiring. Pretty nice.

Jsquared24 (author)2012-10-02

Is that your Halo Reach matchmaking armour? Any, this is a really awesome build! Good job!

Why yes, yes it is! lol Thanks!

joshua.g.wood (author)2012-10-01

can you make a step by step on how to make it

I'm actually working on armor from Mass Effect, I will make a step by step on that as I go. It is the same process, stay tuned!

JTMLB26 (author)2012-09-30

Just curious . . . when you pull the trigger (if you even can) does the number of ammo go from 32 to 31 and so on? If not you should try to find out a way to do that. But even without that it is still the best and most realistic halo armor ever!!!! No joke!!! •~• cool face isn't it!

The Irish Cowboy (author)JTMLB262012-10-01

I had the electronics set up to do so, unfortunatly the nerf gun mag system interfered with the trigger so its just a button on the side for the countdown, the battery pack fits nicely into the "mag" and the on/off is in the gap between the grip and mag! And thanks!

jonnybo111 (author)2012-09-28

Really nice job irish!
Have you looked at a website called 405th?
You should really post a topic on it.


I am actually a very involved member! :D

bioboy725 (author)2012-09-27

This is great, and I've been planning on doing this ever since I saw them do it on backyard fx.

toezar00 (author)2012-09-21

:D :D :D :D!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

lotrsam11 (author)2012-09-21

Dang. Nice!

curious youth (author)2012-09-17

this is the most realistic armour i have seen. like ever. just wondering roughly how long did it take you to build ? and how much did you spend ? cheers and thankyou :)

thanks! It took me about 2 good years of hard work and I spent around 500$ overall. I appreciated the comments!

snappydragons (author)2012-09-14

this is neat! i love it!


megaduty (author)2012-06-03

That is excellent looking Halo armor Irish!

A big Thank You to you both!

ilpug (author)2012-06-04

Make a How-To NOW.

One of the best builds I have seen.

About This Instructable




More by The Irish Cowboy:Modeling Props for 3D PrintingHow To Make Foam ArmorArc Reactor: First Generation Designs
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