First Foam Build

Hey all. I don't have a lot to show today, I was going to do a fair bit more on the build this afternoon after work, but Ive gotten home and Im feeling pretty beat, so I've only done the base coats of paint, still needs weathering and finishing, but I didnt want to rush things and especially when I wasn't really in the mood for it ether, Ill just end up doing something Ill regret later. Maybe when I get a day off soon Ill dedicate some more time. The base coats consists of 2 Camo green Plasti dip to One almost dusting like light coat of a color called wilderness green, its like a grey green moss type color. It looks a little light at the moment however the weathering and battle damage will sort that out.

Hey guys and gals, SOOOOOO !! the cod piece is done whoooooo !! Since my last post I did added a bit more detail on the rear of the belt and I also thought it needed something extra, so I added a light at the back in the center. Then painted it all up and gave it a clear coat to finish it off. here she is guys.



I also added battle damaging and scaring just like the chest piece and tried to keep it pretty consistent with the chest pattern.






So for the light diffuser I used the same technique as the back of the chest piece, I get some clear hot glue and fill up a layer on some clear thin plastic, like the top of a clear takeaway food container, then once its cooled I cut out the desired shape and and place it neatly in a counterpart hole in the suit, making sure the flat food plastic is facing outwards, as in its the bit you see. Then using a heat gun lightly heat it up and as the glue melts again it slightly sets in place, its strong and doesn't seam to come out,but not to the point where if i need to take it out, that it will rip foam off, Its cheep, easy to replace and I think it yields pretty good results. All the wiring and electronics I was able to rig up and tuck away neatly in the back as well so I pretty happy with that.











Not sure which piece ill move onto next, thinking the shoulders maybe the thighs. which piece would you guys like to see next up ?

Looking good! I like the color scheme and the lights you added in. Can't wait to see it when it's done!

That is one nice cod peice man. Your building and painting skills are superb. I can't wait to see more progress shots.

i am in awww of the detail! one of the best foam builds i have ever seen.

Amazing project, unbelievable and really confidence-building. I'm planning to start a Destiny build this week, and this just convinced me to go the foam route. I have a couple of questions though.

What are you using for those thinner layers of foam? Also, what tools are you using to shape/shave the foam? Exact-O knives? Razor blades? Hot-glue to hold the layers together? To fill in the gaps are you using drywall paste? I know you said the "soft stuff", but I have no idea what that is. Can you mention a brand name or something so I can find a similar product here in the US?

Hey all thanks for the awesome comments. I can't wait to post up more pics. as far as what I've used and tools and things, I won't get a chance to go into the workshop for a few days, but I promise I'll post some pics and drop some brand names and things when I get a chance.

HELLO 405th, Sorry its taken me a few days to get this info up, shift work is a bit@#. Anywho as promised Ill show you the tools and materials I use.

Foam:

I use 3 layers/thicknesses of foam.

1) Standard EVA foam mats for the base.


2) I'm not sure if you can get these in the US of A but here in AUS, I get them from Kmart. They are food and water mats for pets, they are still EVA foam so they bond well with other materials and hold there shape when heated and cooled.
They are approximately 5mm thick ( 0.19685 of an inch, I pre googled this for my US friends in here ).

3) Now this is just standard craft foam in multiple colors, they come in a pack of about 200 or so here. I get them from Spotlight Australia. they are about 2/3mm thick. (0.0787402 of an Inch).


Tools:
I'm just going to list these with a photo next to them.
1) Hot glue gun ( I use a smaller type, as its easier to get into smaller tighter spots if needed.)


2) Cheep Heat gun ( I say cheep, just to show that this can be done on a low budget ) I believe I paid $15 Aus for mine.)

3) Hot Knife ( once again cheep, however I do step it up on the blades, otherwise in the long run it would end up costing me more in replacing them anyway.)

I also use whatever I can get my hands on for shaping, making particular details or just nuts and bolts type things to add more layers and details to the build. Anything lying around the house that suits my needs.

Finishing and Painting:

ok so to start this process I begin my filling in any visible holes and gaps with a drywall filler (brands and type is exactly the ones I use in pictures below.)





I then spray a coat of primer paint to highlight any further imperfections and fill accordingly, then a second coat of primer is applied.
3rd is 2 coats or more if warranted, of the GREEN CAMO plasti dip rubber coating.
then 1 light coat of your choice of paint. Mine is called pale eucalypt, I think I said it was something different in an earlier post but this one is the right one.
Then I heavily water down some black and brown acrylic paint, separately. Applying it with any old brush, this part doest have to be particularly neat, but I make sure im putting it only in the gaps and corners where dirt and grime would normally collect, I do a little bit at a time, them wipe it away with a common dish sponge, when I do this it wipes out onto the rest of the suit and creates that weathered and used look.

Then with any old brush again, the crapy-er the better, spray it with some chrome paint and dry brush in some scratching and bit were the paint would wear away.
Now this is the part where I get a little antsy about but I really go over in my head for a while, thinking and pondering placement of damage and gashes. Then with my hot knife tool i start to make cuts and marks in the suit. Once Happy with the battle damage I give them a really quick spray with black paint, making sure not to get to much over spray on the surrounding areas, a little is ok because it gives it that tarnished burnt look. Then once that has dried I take some more black acrylic and fill in any spots I missed with the spray and then apply some more dry brushed chrome over the top again.
to finish I give it a coat of a clear matte sealer.

THEN TAAA DAAAAH !! it's done.

If you guys have any specific questions on how I do something exactly just ask and I post up more.

Hi again,
Didn't know if I would have much done today with this piece, A lot of its shape and construction was experimental, so took me a little longer. All I had were tons of reference images and I had pepakura viewer open, so I could use the 3D pep file as a reference point too. But its all from scratch and drawing up my own templates on card first then onto foam. I've only started one so far, because I wasn't sure how it was going to turn out , making sure i took notice of the steps i was taking to achieve each bit and putting my templates aside for the left shoulder, when it comes time to do that one. this is what I have so far on the right shoulder.

That looks really amazing. Keep up the great job, cant wait to see how it turns out.

So ive decided that the quality and level of detail in the shoulder piece that Ive started was not to my liking, so I started a new set of shoulders here what I have so far. Little more research and planning put into these ones.

Wow dude, just when i thought it couldn't get any better, you go and out do yourself. These are looking amazing.

You're really went above and beyond with this man. The amount of detail on the weathering and color is just awesome.

Damn. The paint and weathering. I'm glad I took the time to read all this. There's a lot of really good information here. Good job man. Damn.

Thanks again y'all

Hey 405th, sorry I have been AFK for a while, Ive been very busy the last few months and over the Christmas period, I got Halo 5 over this period too and played it all the way through on easy just to get the feel of it, wasnt that impressed. Went off halo for a little while and started to fall away from its light and awesomeness. I then decided as with all the previous games, that I needed to complete this game in legendary of course. I started to gain a little more appreciation for it and my motivation for my suit project slowly crept back in. So First day back in the workshop today, and hoping to have some details and more posts coming up soon.

Well its about time you showed up!!
(I'm kidding:angel) great to have this build back on track and i cant wait to see more!!!

Nice to know I was missed haha. Thanks .

Ok guys and gals, after a putting this build off for a few months, I finally have something to show you. I believe one of my last post was about the shoulders and how I was constructing a Halo 4 version for this build however, since then I feel that it just wasn't working for me, so I started on a second set with a more halo 3 look and feel to it, looked ok but for some reason while constructing it I wasn't matching it up with the parts of the suit I had already finished and I ended up making it too big. Now that this project is back on track I started a third set with a little more thought and time in it. I'm yet to add finer details to it but I have the Left shoulder base down. I got myself Pepakura Designer instead of viewer and I modified some Pep templates to make my own foam ones as I could not find anything suitable. Once I have decided on and finished the smaller details and electronics, I will just repeat this piece in reverse for the right arm, then maybe move to the forearms and hand plates.


Excuse the quality of the pics, they were taken kinda hastily with my phone.

Hey Hey 405th.
So just a small update on the progress of the shoulders, I have one completed, well construction anyway and am about to glue wash it, which is a process I think I forgot to mention in my earlier post with all the materials and my methods in it. It's not a lengthy task however for those who are unfamiliar with it I will post a detailed description of it in my next Update. So I've added all the smaller details needed, there might be more that I add later as I go but for now I'm pretty happy with the way it's looking. I've also done the wiring and battery work for the lighting and made the Hot glue lens diffuser for it too. Another process I can document later If you wish. I'm tossing up now whether to paint it or make the opposing shoulder then paint together, I'm not worried about inconsistencies with paint at this point as I have my process nailed now. Any way as always lemmy know what ya think so far guys.

PS: some of the gaps are a little larger then Id like, but im not worried, that can all be fix just before paint, as well as fixing and surface glue marks.


I will most likely put a cover over the battery and light assembly too.