How To Make Halo Armor

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It's easier than you think to make "Halo" armor that looks pretty damn cool, even on the cheap. Whether you're a cos-player, looking for a costume for Halloween, or just want to stand out on the battlefield, "Halo" armor can be had for about 100 bucks and a little skill—then you too can be styin' like Master Chief.

What you'll need to make "Halo" armor:

  • Pepakura Design Viewer : free software to view and scale armor blueprints
  • Armor blueprints: linked at end of article
  • Ream of heavy card stock or 10mm foam floor mats
  • One can clear Laquer spray
  • Glue
  • Two Aqua Resin starter kits
  • Two yards fiberglass insulation mats
  • Four feet velcro
  • Three feet 1-inch foam padding
  • Nylong straps and buckles
  • Visor
  • Black gloves
  • Black clothes
  • Spray paint: primer, silver, and color of choice
  1. Scale and print your armor blueprints. You will need to scale the armor to fit your height, as it starts out at seven feet. Once done, print them out either onto the heavy card stock, or regular paper if using foam. Foam is great for paintballing; card stock can be used in any other setting. 
  2. Cut out and assemble the armor pieces. Fold them along the solid lines, and glue together into armor shapes. Spray the completed pieces with laquer to waterproof it. If using foam, trace the printed patterns onto the foam and cut those out. You don't need to waterproof the foam. 
  3. Coat the pieces in Aqua Resin. Paint a thin layer on both the inside and outside of the pieces. Clean up and drips and make sure its evenly coated on one side, let dry for about an hour then do the opposite side.
  4. Add the fiberglass to the inside of the pieces. One or two thin layers will do on the inside. They should kind of look like dryer sheets (in small pieces) before you apply them. Add another coat of Aqua Resin and let dry for two hours.
  5. Carve out some details with a sharp tool. You may want to add some battle damage to give the armor a more "used" feel. Consult screenshots of MJOLNIR armor to get an idea of the details. 
  6. Paint your armor. Spray primer coat, and let dry. Spray a layer of silver, and let dry. Spray with the color of your choosing. After the final layer dries, get a piece of fine sandpaper and gently buff the armor to weather it. Repaint if you mess up.
  7. Add the straps and padding. Don the black underclothes, and attach straps and glue in padding until the armor fits you the way it should. This can be time consuming tedious work.
  8. Insert the visor. Use a cheap motorcycle replacement visor Don't add it until you've painted all the pieces. You may want to refrain from glueing the helmet together completely until you've inserted the visor.
     

Tips and Hints:

  • Be patient! The whole process can take months, and you may need to restart pieces many times. 
  • Wear a face mask or respiraptor, and safety goggles, when working with hazardous materials.
  • Work in a well ventilated area
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