help with armor making

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If you want to burn the hell out of you workspace you use a soldering iron.

Foam cuts very easily with a sharp box cutting knife and an xacto blade. Invest in both of those plus a sharpening stone and your set to deal with foam.
Best program will always be Pepakura Designer. As said before, you will be scaling your armour by hand (figuratively speaking) so you need the program that will allow for that customisation.
As to material choice, its all up to you. Foam is cheaper at first if you know a reliable and inexpensive supplier. Foam is also has the advantage of sculpting detail. With fibreglass you must first create the suit in cardpaper first, then resin coat, then bondo and then prime for painting. Foam is basically 3 steps: cut and glue, prime and then paint. Foam was my choice and the suit, though to big by my own fault, was pulled together in about 2 months of work every other day.

Now for the models your going to need, the only Halo 2 model you will need is the Hand Plate, the rest of the suit is the same in Halo 3 and that is where you will find the a variety of models that range in detail. As this might be your first suit, DON'T GO FOR THE HIGHEST DETAIL, you will not achieve that detail on your first go. That will take time and practice.

Welcome to the 405th
 
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