Halo Master Chief Suit

This was my first attempt to making a full scale, costume replica build...

The beginning process of printing and cutting out shapes...

1. I first start with building the helmet. I used card stock to cut my shapes out. and used regular clear tape to hold the shapes in place.

I made a few different types of helmets, just to see which one i was willing to commit to in the end.

I first added layers of fiberglass and resin to the INSIDE of the helmet. Then after i was satisfied with all the voids filled, i let it dry for a few days. Next i spread bondo mix on the outside to make the surfaces smooth and seamless.

It took a bit of time. I cant remember how much, considering this was my very first fiberglass and bondo project.

The electronics were simple, just a few led's that are powered by a 9volt battery.

Much like the helmet was done, the body was done the same way, just took a long, long time.....

This is where the true art process takes place, because now the parts have to try to fit the person you made it for...

I attempted to make a few guns as well, just to complete the suit...

Here i attempted to make a wood 2x4 construction to hold the body pieces in a statue form. After wearing it for a few events, i decided to modify the abs piece and a few other parts to make wearing it easier...