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Thread: Zat German's Halo: Reach - Foam Armor Build WIP

  1. Zat German's Halo: Reach - Foam Armor Build WIP

    After about a month of being busy with work and personal things as well as doing research into various materials and tools, I finally started my Reach armor build. I really wanted to build a Mark VI suit first but it is much more complicated to build out of foam than Mark V[b]. So I decided to cut my teeth on the Reach armor and then maybe make some Halo 3 stuff.

    My primary build material are EVA foam mats from Harbor Freight. You can also get these mats at Walmart as a Gold's Gym brand and Big Lots. The Walmart and Big Lots versions have diamond plat rather than the houndstooth-like pattern of Harbor Freight's. When on sale, Harbor Freight's mats are the cheapest I have found, with Big Lots being cheaper off sale. You can also get these mats in various colors online but all the sellers I have found so far really gouge you on shipping.


    Here is a shot of the first pieces I cut out. I started out using a hot knife(shown at the bottom of the picture) but after remembering that I have a mini-jigsaw, I started using that exclusively. It works great. It does produce edges that will need more cleanup but it is super fast to cut with. You can see a picture of it in the tools section at the end of the post.


    Here are the patterns I initially cut out from the Pepakura file. I am using lganderson's version since it is the most accurate one available to-date. L3X's would be nice to have but it is still in the process of being unfolded and is not available.


    My assembly progress so far, as of this post today.


    Here is a picture of the underside of the armor. I used the electric knife to cut out these angles but as you can see I cut out way too much. It is okay though, because another layer of foam will cover all of this up. I may try filling it in with some Foam Coat+Bounce, to see how well that works as a gap filler.


    On the top side of the armor, you get all these gaps here where the hot glue did not reach. I do not feel like cleaning off a ton of hot glue, so I am using just enough to join pieces without it squishing through the top, if possible. You can fix these gaps quite easily though thanks to a tip from a friend.


    The tip: Use superglue gel! Just put a little in the gap and squeeze the two parts together for about 30 seconds. After that, the gel will hold the two parts close together. The excess that squeezes out can be wiped off. Wear latex gloves unless you like superglue all over your fingers.


    Same gap after it has been glued with the gel.

    Tools Section

    This part of the post will be kept up-to-date with all of the tools I have used for the build. I figure this may be a useful reference to anyone getting started with foam.

    1. Proxxon Jigsaw: For cutting out patterns
    2. Electric Knife: For making miter cuts
    3. Hot Glue Gun: For gluing parts together
    4. Hair Dryer: For shaping the foam, hands friendlier than heat gun
    5. Superglue Gel: For closing up gaps

  2. #2
    Join Date
    Jun 2009
    Location
    the good ol' glove
    Posts
    531
    Looking good so far. Its nice to see another foam build, I'm just about to start mine, so this is a great help.
    "Drink cactus juice, It'll quench ya, nothin's quenchier, it's the quenchiest!"
    Click here to see my foam reach multiplayer character
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  3. #3
    Join Date
    Oct 2010
    Location
    Witham, Essex UK
    Posts
    197
    Blog Entries
    2
    Looking good love to see how it turns out
    My Custom Halo Armour: http://www.405th.com/showthread.php/...h)-Armor-W.I.P
    Helmet: Pepped

  4. #4
    Join Date
    Oct 2010
    Location
    Canton, Ohio
    Posts
    75
    Blog Entries
    5
    nice start cant wait to see it all done

  5. #5
    Join Date
    Sep 2010
    Location
    University of Oklahoma
    Posts
    431
    GREATNESS!!! Lovin your work so far brah!
    CHECK OUT MY HALO 4 MASTER CHIEF!!HERE

  6. #6
    looking good glad to see the use of superglue to seem the gaps! Now i know where i can add more detail to my armor. thx! Best luck , I cant wait to see more!
    Never underestimate the power of stupid people in large numbers....

  7. #7
    Join Date
    Sep 2010
    Location
    Orange County, CA
    Posts
    281
    Quote Originally Posted by jimbo_only_one View Post
    looking good glad to see the use of superglue to seem the gaps! Now i know where i can add more detail to my armor. thx! Best luck , I cant wait to see more!
    I agree!! I'm going to have to try this method because trying to go over the hot glue and trying to smooth it out is a really pain. Where did you get the gel at and do they sell it in larger packages?

  8. Quote Originally Posted by WrathPrime View Post
    I agree!! I'm going to have to try this method because trying to go over the hot glue and trying to smooth it out is a really pain. Where did you get the gel at and do they sell it in larger packages?
    You can get the Loctite superglue gel just about anywhere. I have seen it at Hobby Lobby and Target for sure. It is pretty common stuff. I have not seen it in any larger package but you do not need very much for these seams. It is about $3.50-$4 for one of these bottles. The friend who told me about using superglue gel said he used stuff from the dollar store but he had big problems with the amount of gel he would get per package. I just decided to use a known brand so I could avoid having to go back a bunch of times for more.
    Last edited by Zat German; 11-10-2010 at 12:43 PM.

  9. #9
    Join Date
    May 2008
    Location
    Winton California
    Posts
    2,954
    Wow! Deffinately going to stick around this thread to check up on progress pics!

    -Pony
    Orbital Drop Shock Pony ODST Build.
    http://www.405th.com/showthread.php/...808#post514808
    ODSP: ORBITAL DROP SHOCK PONY
    "Ponies, we're raining love from above!" GT: WarPony38

  10. #10
    Join Date
    Sep 2010
    Location
    Brisbane, Australia
    Posts
    33
    Looking Good, Zat! I'm still thinking about how I'm going to approach my build, which will likely be a hybrid of different materials.
    Wonders will never cease...

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