Have you ever woken up one day and decided man I could really use some custom Master Chief armor? Well we did, and we set out on this crazy time consuming adventure. After a few clicks on Google we came across the 405th, which offers templates for most of the Halo armor. You will need to download a program called Pepakura. If your looking to build armor, 405th has plenty of info. Our goal is to have two sets of armor ready for PAX this year….. let’s just hope it’s a rainy summer.

At the moment we are mostly in the paper building stage. Next we’ll be using a resin/fiberglass. After that a clay/bondo, then we’ll start creating molds. Last stages will include under armor, paint, and accessories. The cost of this project is expected to hit about $800.00, but having custom armor is priceless!

Next I’ll break down the progress and amount of time spent

Every piece started out as a huge mess of a puzzle on the floor. We’ll be finding little pieces of paper for years to come.

One huge puzzle

Helmet: 16 hours (done twice, The first one was to small)

Chest: 5 hours

Biceps: 7 hours each (built 3 times, one was too small)

Forearm: 9 hours so far (working on second, first was too small)

Belt: 7 hours

Thigh: 6 hours each
Calf: 6 hours each

Boot: In progress 1.5 hours
Total time: about 82 hours at least (not including size testers)

The final project should look a little something like this.

Stay tuned for progress updates.

For more info: http://www.405th.com
http://halocostuming.wikia.com/wiki/Pepakura_File_Index