How to Make a Halo 4 Master Chief Costume

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This is my tutorial on how to make a Halo 4 Master Chief costume/cosplay. The main building material will be EVA foam and craft foam for details. The EVA foam can be bought almost at all home improvement stores and  the like. I will be using 1/4" EVA foam from a foam shop nearby. The craft foam can be found at Michaels, Ben Franklin and other craft stores.
The other materials/tools are
-A carpenters knife
-Hot glue & Glue gun
-Paper, pens, ruler etc.
-Spray paint-Krylon Italian Olive
-Cardboard
-Small lights(led's or miniature christmas village spotlights that can be bought at miachels around christmas time.)

Step 1: Guide Pictures/ Objects

Instead of using pepakura, I made all the parts from scratch as I found out that pepakura is insanely complicated. Though pepakura can be useful for guide pictures/models. After my computer crashed on me, I went to use a master chief action figure that worked pretty well.  

Step 2: Making the Cardboard Frames/ Templates

For the Chest/ Torso I made a cardboard model of the piece first to make sure that it fit ( since I don't have unlimited EVA foam) then traced out the pieces onto the foam and assembled. With the helmet I made a base piece out of cardboard that just added durability/ stability then added craft foam and EVA foam to complete. For the cardboard frame, I made small(ish) boxes to hold the lights in the helmet.

Step 3: Making the Rest of the Armor

For the rest of the armor, I made the base piece(s) out of EVA foam and the details out of craft foam. As an example, the thighs were one piece of EVA foam just wrapped in a circle.

Step 4: Spray Painting

Just an FYI if you don't already know, spray paint fumes are toxic (if you don't believe me, I killed a spider with it!) so proper safety gear is a good idea. This includes a natural vapors mask and safety goggles. Also ventilate the room well. Ok enough of the blah,blah, blah. I built a simple painting rig made of a wooden dowel taped to the top of a large bucket for those round pieces like the forearms and thighs. For the rest of the pieces, I just put them on the ground. (If you didn't read the list of materials, the spray paint I used was Krylon Italian Olive.)

Step 5: Extra Details and Water Proofing

You can add other details like the 117 and scratch marks. These were made by taking a coarse brush, dipping it in silver paint, lightly brushing it on a piece of scrap paper until the paint marks are like scratch marks or desired look. To water proof the entire thing, I used SOFSOLE Water Proofer (invisible, works UBER WELL, I mean it water proofs frkin paper towels!)

Step 6: Done!

Now you are done with your halo costume! You can show it off to friends, get extra candy on Halloween, or just be awesome!

Don't forget to comment and subscribe, and stay creative!

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    52 Discussions

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    ms3911

    1 year ago

    Can you make a template print-out for the chest piece? Please?

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    killertiger044199

    2 years ago

    can you make a tutorial for the pistol too?

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    MessyWestP

    2 years ago

    HOW DO YOU MAKE HELMET PLZ IVE BUILT EVERYTHING IN IT EXCEPT FOR HELMET

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    JosephH66

    2 years ago

    can you show me how to make the vest

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    TerrorKitties

    2 years ago

    can you make ODST armour tutorial for me pls?

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    TerrorKitties

    3 years ago

    question: what age group does this fit, and can you make a version with improved mobility, since this doesn`t look to flexible.

    1 reply
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    Parkour is literally my favorite thing ever (sadly I suck at wallruns, especially horizontal) so yes, make it for mobility. Also, try editing this for mobility