Introduction: RvB Simmons Halo Armor

Picture of RvB Simmons Halo Armor

Here we have basic Mark 6 Halo armor from Halo 2 and 3. Mine was painted maroon for Simmons from Red vs Blue, but it can be painted any color, so grab your foam and knife, and lets build some armor

Step 1: Templates

Picture of Templates

First and foremost come templates. I picked up mine from the RPF at this link:

You load these .pdo's into pepakura, scale, print, and tape together any pieces that were too big for one page.

You can also decide to put together pieces to form a bigger piece, but that is personal preference

Step 2: Putting It All Together

Picture of Putting It All Together

You take your templates, and trace them onto your eva foam (I used 1/4 inch foam), then you glue pieces together were they come together on the pep file. When the pieces don't line up flush or a 90 degree angle you need to cut the foam edge at the required angle by angling your knife. You can use hot glue, crazy glue, super glue, or even contact cement. Be patient with this, it took me a couple months to finish this.

Step 3: Artistic Liberties

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In the interest of time, I took certain artistic liberties. For example I changed the foot armor to something simpler and quicker. I also omitted the back panel of the shins. These are decisions I made that changed the quality but also the time taken for the armor. Make these kinds of decisions as you go.

Step 4: It Looks Ready to Paint, But It's Not

Picture of It Looks Ready to Paint, But It's Not

Don't go and paint the raw foam. The foam will only absorb the paint which mean, you apply paint, but the paint just disappears. You need to seal the foam. I used black Plasti Dip, because I had some around, easy to apply, and drys quickly. This stuff can get expensive, making Mod Podge (or a water white glue mixture) a cheaper alternative. Be wary, Plasti Dip remains flexible, whereas Mod Podge or white glue will crack when bent or stretched. More layers is always better.

Step 5: Now on to Paint

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Once sealed, grab a can of your preferred color and paint that sucker with at least 2 coats. But now the armor looks so brand new, never seen a battle before, but we'll fix that. Using rub'n'buff silver leaf metallic finish, put that on your finger and smear that where ever there should be some wear and tear. That mean most protruding edges, but also in random spots all around. This part may get tedious, but it's one of my favorite parts and in the end is makes so much of a difference.

Step 6: Helmet Visor

Picture of Helmet Visor

These things get tricky. After making mine I found a better way of doing it. Using something mirrored like this mask: and then putting a transparent, yellow stage gel overtop of it. Cutting the chrome mask to the shape needed is required, but some extra room can be left if being applied from the inside. Mine was then secured with hot glue.


Tesla871 (author)2017-11-07

Also, how do you weather the armor in certain spots?

Toasted Bagel (author)Tesla8712017-11-07

For this set I just put some silver rub'n'buff on my finger and smeared it around anywhere I felt like there should be some weathering. This creates the look that the top coat of red has chipped off to reveal some sort of metal underneath

Tesla871 (author)2017-10-27

how do you make the helmet?

Toasted Bagel (author)Tesla8712017-11-07

The helmet was a whole separate adventure that involved 3d printing about 20 separate pieces. Special thanks to Big Red Frog for making his helmet model public on thingiverse. This is the page where I got the models

brennus.fogarty-pryor (author)2017-05-24


EthanJ34 (author)2017-02-28

cool i have been trying to find someone who has made rvb, armor thats cool.

genghisbunny (author)2016-11-09

(Great job)

genghisbunny (author)2016-11-09

This ain't no ice cream social!

Anirudh Ralhan (author)2016-11-08

That's so cool!!!

Swansong (author)2016-11-08

This came out really well!

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