There is a way to build metal armor. I have been issues finding it again but someone on here built a very nice set out of 22 gauge steel sheets if I remember correctly. Between tin snips, a lot of hammering, and welding it together. As far as Pep goes make sure to read all the stickies at the...
Individual armor pieces Master Chief MkVI
I have been looking for just a high res 3d Model of each piece but I can't seem to find one.