Picture of How to build Halo Armor
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

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!
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talonsblade4 years ago
Measure how big the the guy is in the picture, then how big the armor is in comparison
MotaBoi (author)  talonsblade4 years ago
That's exactly right
Red hood2 months ago
Somebody call me if you can help my number is 254-833-3453
Red hood2 months ago
Somebody call me if you can help my number is 254-833-3453
Red hood2 months ago
Please help I'm trying to make a red hood helmet and have no idea how
wraith1099 months ago

I would like to use this method on another project, and I am curious, can I use fiberglass resin on poster board foam?

zeroaxe1 year ago

Dear MotaBoi and everyone else that want to work with fiberglass,

If I may, having worked with fiberglass a lot in the past, may I give some tips?

1. Do not cut your fiberglass. Tear it in squares instead. The reason for this is because when you cut the fiberglass, you have 'hard and straight' edges. when you overlap the FG, you get hard lines. And there is a change that you can trap air under the one mat (see my crude image from MS Paint ;) ). The blue is supposed to be an air bubble, lol. When you tear the mat and overlap them, you have soft edges that 'disappear' when they over lap and resin is applied. OF COURSE, if you don't mind the 'hard edge' look, or it is just to create a master mould, this should not matter.

2. Using torn mat will reduce sanding down ridges caused by cut mat.

3. The original poster mentioned dabbing the resin on the mat. Reason for this is to get rid of air trapped under the (wet) mat being applied. See it as if you are stabbing at balloons with a needle. Or popping bubble wrap (cause everyone just LOOOVVEESSS popping bubble wrap! ;) )

There are still a lot of other tricks of the trade working with FG, but for this instructable these these are of most relevance.

Thank you for the link for the HALO Mark VI helmet. I hope to start with mine soon!

Happy building people!


Oh yes!

4. Once you have your mat, bunch it up a couple of time (as if you are making a paper ball to slam dunk in your office dust bin). The reason for this, is that you 'break' or 'crumble' the hard FG strands a little, and this helps getting FG around corners or in concave 'dips'/holes.


19freemans1 year ago
Can you put up a way to build a E.O.D armor set
Hey! This is amazing! But is there any way you could send me the link of the chest and possibly the feet? Also, all of the tutorial YouTube links aren't working. I'm stoked to get this project rolling
I'm gonna try this.
How do you size it looks great
That looks really dam hard
Hi i dont understand the part of the scale can you help me, im 1.72m
kcowan32 years 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.
trentmyster2 years ago
If I plan to buy a visor for the MK VI, do I need to make the visor in the paper cutouts?
ranndoo2 years ago
Sorry I meant can you do it with the file viewer.
ranndoo2 years 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~4 years ago
WHERE IS THE LINK TO THE ARMOR??!?!?!?!?!?!!!???!??! GAHHHHHH!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
MotaBoi (author)  ~Aeronous~4 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~4 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~4 years ago
Haha sorry :( try again :P
WOW is that you?
I am. Thanks.
http://halocostuming.wikia.com/wiki/Pepakura_File_Index 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~4 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~4 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~4 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~4 years ago
Could you please vote for me ? :D
NVM, I voted. You have 14 votes so far.
MotaBoi (author)  ~Aeronous~4 years ago
Thanks! :D
DEFINITELY, I already planned on it. How though?
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