How to Make Foam Halo Armor

Introduction: How to Make Foam Halo Armor

Have you ever wanted to own your very own Master Chief Halo Spartan armor, or any other armor for that matter? Well look no further as you can make it yourself! For this project we will use 10mm foam floor mats and 2mm crafting foam. You will need a hot glue gun to stick your shapes together.
If you need materials, tools, tutorial videos and more pictures be sure to visit

Other related Halo pages
Master Chiefs Xbox 360 armor (fiberglass method)
Mark VI Challenge (foam patterns)
How to make Halo weapons (patterns and instructions)
Master Chief Pictures (pictures of this and the fiberglass suit)

Step 1: Get Your Armor Files

The first thing you will need are some .pdo files of the armor you wish to make for use with a program called Pepakura Designer that you can find as a free download online.
A good place to look for armor files is or wikia costuming (do a google search)
You will also need lots of reference pictures or a detailed model of what you are making, you can find those on the wikia site too, in case you don't own the game.

Step 2: Make Your Patterns

For this step you will need to do a little math as the Halo spartan is 7' tall! Figure out your size compared to 7' and reduce the scale by that amount. Then print your shapes and tape them together where you dont want a seam. If you want to skip this step you can find the patterns for the suit pictured here:

Step 3: Cut Out Your Foam

Cut out your patterns in the 10mm foam and glue them together with hotglue. You can use the 3mm foam for bass relief details and a wood burning kit for other detailing. For best results use a hobby crafting hotknife attachment and also seal the foam with heat first.

Step 4: Paint Your Armor

Once assembled you can paint your armor with Plastidip spray paint, 2 coats should do, then a primer and finally your chosen colors. Highlight details black for valleys and drybrush silver for a metalic look.

Step 5: Show Off Your New Armor

Impress your friends, scare small kids, whatever suits your fancy.
Remember to visit if you need materials, tools or tutorial videos.



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    76 Discussions

    I doubt that anyone here knows what Half-Life is, or who Gordon Freeman is, but do you know where I could get a template for his H.E.V. bio-hazard suit armor? This is a good method for making armor. look it up if you don't know.

    3 replies

    Fam, I would have flood over headcrabs, any day

    How do you take it off though is my only question?

    Can you please post the templates for the right arm arm?

    Can you please post the templates for the right arm arm?

    Can you please post the templates for the right arm arm?

    cool could someone make a odst armor or something and upload it I would like to try and make one for an art project

    For scaling, take your height, add 4-6" to it for room, then divide that by 86,take that and multiply it by the current scale=scaled to you!

    1 reply

    You have a great idea. maybe next time as a challenge you can make ODST armor with foam

    I am wondering how you printed it out so that the template pieces were bigger. I printed the helmet and it came out really small.

    Awesome outfit! The Squidoo link (near the top) is now dead. Curious if that's your Squidoo page that it links to and if it's going to be fixed....viewed it once and really wanted to go through all the material again before starting my outfit! Thanks