How to build Halo Armor

Contest Winner
Hey guys, this is my entry for three contests!  Halloween, Office Supplies, and Gorilla Glue!  I'll be showing you how to make Halo armor!  I really need to add more to this intro..  what should I add?

PS.  Vote for me!!!  :D
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Step 1: Materials

Picture of Materials
Cover/card stock
Butter knife
Exacto knife / box cutter
Cutting board
Glue  (If you like, use gorilla glue.  It is stronger, but in the long run it won't make any difference after fiberglassing, but any glue would work.  The reason I have chosen this one is just to save money)


Pepakura Viewer

A helmet file to be used with pepakura:
RECON  by Kirrou

In my opinion, the MK VI is the most difficult, but it is the most popular.  If you want simpler models, then just post a comment and I'll give you a link to one!
talonsblade3 years ago
Measure how big the the guy is in the picture, then how big the armor is in comparison
MotaBoi (author)  talonsblade3 years ago
That's exactly right
WolfGhost173 months ago
I'm gonna try this.
wstringham6 months ago
What kind of fiberglass did you use and how much did it cost
cviramontes18 months ago
How do you size it looks great
TobyZilla1178 months ago
That looks really dam hard
Hi i dont understand the part of the scale can you help me, im 1.72m
kcowan38 months ago
MotaBoi, what was the average cost to only make the helmet? And then the full armor? I'm going to Nashville TN for comicon this fall and would like to try and craft this.
trentmyster9 months ago
If I plan to buy a visor for the MK VI, do I need to make the visor in the paper cutouts?
ranndoo9 months ago
Sorry I meant can you do it with the file viewer.
ranndoo9 months ago
Can anyone tell me how long it took them to finish it and if they know how to down size a pepakura file? Thanks(:
~Aeronous~3 years ago
WHERE IS THE LINK TO THE ARMOR??!?!?!?!?!?!!!???!??! GAHHHHHH!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
MotaBoi (author)  ~Aeronous~3 years ago
Sorry I'm not finished these instructions yet I dont know why its already posted :S
What do I have to do once I have my height? What do I change?
MotaBoi (author)  ~Aeronous~3 years ago
Sorry, I'll post on your wall or something when I'm done. You should work on the helmet for now.
Aww crap. When I printed it, I did all the pepping, but I accidently scaled it down to fit on my page. I guess a kitten could wear it.
MotaBoi (author)  ~Aeronous~3 years ago
Haha sorry :( try again :P
WOW is that you?
I am. Thanks.*The-Official*-Halo-Reach-Pepakura-Files-Thread here's a couple links
I compared the height of Master Chief in his armor (84 inches) to my estimated height while wearing halo armor of about 58 inches by 84 divided by 10 to get a 10% size of Master Chief and plugged in numbers until I got the closest size to my estimated height which turned out to be 58.8 inches. Using this method, I got a PDF scale for printing the armor of about 70%. I think it would be a good idea if someone released t full scale PDFs of total sets of Halo/SciFi armor and left equations and methods for finding the right PDF scale.
~Aeronous~3 years ago
Hey, I'm using A4 cardstock, and when I printed it, it said that it used different paper, and asked me to adjust the scale.
MotaBoi (author)  ~Aeronous~3 years ago
Go to settings, then print and paper settings. Change it to A4, then also change your actual printer settings to A4
I got my dad to fix up the scale, I now have it reprinted, and I've prepped up to page 7 (Step 3: 'pepping'. Don't you mean prepping? As in preparing?
pepping, as in Pepakura(ing) :) i started my halo armour several months ago to take to comic-con so far i have helmet and half a torso
MotaBoi (author)  ~Aeronous~3 years ago
Nope, it's called pepping. What do you mean page 7? On the helmet?
Don't forget to take pics when you're done :D
can I see some progress pics?
Yeah page 7 on the helmet (it has 12) but I finished that now, I'm gluing it together. I'll post progress pics :D.
MotaBoi (author)  ~Aeronous~3 years ago
Could you please vote for me ? :D
NVM, I voted. You have 14 votes so far.
MotaBoi (author)  ~Aeronous~3 years ago
Thanks! :D
DEFINITELY, I already planned on it. How though?
MotaBoi (author)  ~Aeronous~3 years ago
Thanks! :D
MotaBoi (author)  ~Aeronous~3 years ago
Nice! :D
amazing! I like the good shapes and how accurate it is compared with real halo armor in the games!
MotaBoi (author)  headshothoncho3 years ago
Thanks! :)
PiTBuLL8923 years ago
would the resin make it rock solid so you could sit down without crushing it?? because i got a brill idea, the sixth-form fancy dress the other day a guy came in a predator costume and imagine coming in spartan armour and be able to say you made it yourself
MotaBoi (author)  PiTBuLL8923 years ago
If you do 2-3 layers of fiberglass, then yes. The resin alone won't really do much at all.
MrTinkerer3 years ago
You gonna Bondo? If you are there are a lot of parts on this helmet that are good candidates for "rondo".

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