Build Halo Armor




About: Indy Mogul is the network dedicated to DIY filmmakers and film lovers alike. Our first show, Backyard FX, is a creative and funny 'how-to' guide for making film effects on the cheap. New episode every Monday...
This week on [http://www, Backyard FX] we show you how to make a futuristic set of space armor just like Master Chief wears in Halo 3.

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Step 1: Shopping List

- Ream of Heavyweight Card Stock
- 2 Aqua Resin Starter Kits
- 2 yds. Fiberglass Mat
- Nylon Straps and Buckles
- 4 ft. of Velcro
- A few feet of 1 in. Foam Padding
- Cheap Black Gloves
- Dark Colored Under clothes

Step 2: Get Blueprints From These Sites

Step one is go to this link: and download the free Pepakura viewer. It lets view and print out the blue prints directly on to your cardstock. There is a ton of information and pepakura blue prints at, and or just type in this shortcut to see my guide to get you started.

Step 3: Cut and Fold

Now you can start the cutting, folding and gluing process. Its sort of like origami on a bigger scale.

Step 4: Waterproof the Cardstock

Once you have a complete section of the armor folded and glued you need to waterproof the cardstock with a clear coat. THEN cover the inside and outside with some aqua resin. Aqua Resin is like polyurathen resin but way less toxic and less stupid about curing temperatures.

So one glazing coat of aqua resin on the inside of the carstock form and one on the outside.

Do these one at a time, each coat should take about an hour to cure.

Step 5: Apply Fiberglass

Next you’ll need to add apply one or two layers of fiberglass for added reinforcement. These layers
go on the inside only and use fiberglass veil and some more of your aqua resin! This should take
at least 2 hours to cure.

Step 6: Carve Out the Details

Now that your armor is sturdy you can get in there with a rotary tool and carve out some details. Some bondo or plumbers epoxy can help here but only if you have some extra cash.

Step 7: Paint the Armor

Now we need to paint and distress the armor. My armor is 1 coats of primer, 1 of silver and 1 of flat black.

Step 8: Straps and Padding

So the last steps are padding and strapping. Probably the most frustrating part of the build. Youll need to glue in padding and attach nylon straps until all the armor sits right on your body. That is the basics of building armor.

And for the helmet you can totally use this technique just add a cheap motorcycle visor and add some if your feeling crazy add some light!

Step 9: Warnings and Common MIstakes

Also here are the 5 most common mistakes people make when building their first armor.

1) Not being patient. It can take as long as a year to build one suit
2)Don't fiberglass the outside of the armor, and when applying your veil use small chunks, not big ones.
3)Don't forget to scale the armor to your body. The real master chief you are not.
4)Don't forget the under armor. It can be as simple as dark colored long johns, or as expensive as fancy pressure suits.
5)Not reading the safety instructions. Dust masks and eye protection a must.

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    337 Discussions


    1 year ago on Step 9

    I love this idea and such, but there is one small problem for me and it is this...I am allergic to fiberglass.


    1 year ago

    can i buy one for a good price


    7 years ago on Introduction

    Um, I know this is probably the wrong place, but I would love to apply these building techniques to some Mass Effect N7 armor, but I can't find any papercraft pepakura templates anywhere, and I've looked EVERYWHERE. I've seen plenty for helmets, but I would love it if there were some armor templates out there. I like the carbon-fiber appearance of the EVA foam armor, but I just don't like the idea of constructing an entire suit of armor out of it, even if it is ballistic foam.

    I mean, some pieces would have to be constructed out of EVA foam for flexibility, especially the jointed spinal and abdominal pieces, but I think that resin armor would be so much more durable and better-looking than armor made entirely of EVA foam.

    I do plan on getting into Halo, as yesterday I was struck with a very strong desire to play the games, which I do not have... and I would love to build my own set of Spartan armor as well as N7 armor.

    Any help with N7 pepakura armor templates would be greatly appreciated. Thank you!


    1 reply

    Reply 2 years ago


    3 years ago

    This is awesome! Just one question, where do you get aqua-resin from?

    1 reply

    Reply 3 years ago

    you can get it at al local home depot, menards, or hardware store.

    hope this helps.


    3 years ago

    this looks like a great build, yeah it may take a while to make and the fiberglass is a tad itchy, but it looks pretty worthy of trying, Thanks!


    8 years ago on Step 6

    pls tell me how hard is fiberglass mat because when i make it it will spoil the effect if it bends when its pressed. is is possible that it can be made with out the paper because i was thinking of making each piece separate. as in the forearm will have 2 pieces opposite each other. i was thinking of making this out multiple layers of ply wood laminated together into a curved piece so that it would stay together and curved. thanks :-)

    1 reply

    Reply 3 years ago

    duude, making it out of ply would be one pain in the rear kind of job... I wouldn't take that up if I were you


    Reply 3 years ago

    that's a good question, it probably could, but at the same time, why would you want that? for easier editing or for animating?


    3 years ago

    Absolutely amazing! If you wanted to do it properly though, put graphene on it!


    3 years ago

    I'm thinking about giving this a try in a few months when I have room in my garage and time. I would like to pay someone to do it for me though if the price was reasonable. I can paint it and do the padding, I just need the armor itself made and the helmet. I can do the rest like add detail etc.

    Some things may be difficult for me like making a god helmet and boots. I want the boots to have some heft to them so when I walk it sounds like I'm a Spartan. maybe use some rollerblades without the wheels and paint them plus add some pieces to it.

    Another idea would be to get some thin sheet metal and cut it to lay over the armor and maybe attaché with rivets and an epoxy then paint over it. Not the entire suite but over some of the flat sections on the chest and arms and legs.

    Maybe on the back a small fan running off a tablet sized battery could be used for cooling.

    Anyways, some ideas. As for making it a more functional suit. Kevlar paneling might help but to really hold up against impact you would need a composite that's light weight but strong like carbon fiber but even that's heavy and will only take a few blows from a determined attacker.

    What makes the Halo suit in the game more plausible is the gel stuff between the body and the armor that locks up and protects the wearer. Its circulates temperature and keeps a seal from the outside atmosphere. Also being huge and full of muscles to help carry that suit is what does it.

    So I would focus more on a well detailed and well built suit for show not for use. You can get away with paintball but you will sweat you ars off and probably get it broken after a couple games.