So I've managed to pry myself from Halo 3 long enough to make a post.
The place I've been building my suit, my parents house, was about 30 minutes from the place I pre-ordered my copy of halo 3. They wanted me there at 9ish on launch night to play in the halo tournament before the launch. So what I got completed up until the launch was:
PAINTED
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Chest
Helmet
Groin
right and left hand piece
battle rifle
CASTED
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Back (was still drying)
left shoulder
left forearm
left thigh
left shin
left foot
right foot
I ran out of time

I came pretty close but didnt quite make it.
In the 1st picture I am showing the chest right before we made the mold.
In the second picture you can see the plaster chest mold, the back piece mold. Up top are the helmet and chest piece, along with the groin plate painted. the pieces towards the bottom of the picture are all casted, washed and mostly trimmed.
It was unfortunate to see the suit not get finished before the launch of Halo 3. And halo 3 will definitely cut into my freetime

I do plan to work on it some this weekend and have it completely finished for Halloween.
Once I get the rest of the pieces casted I'll try and get a picture of the whole suit together, even if it isnt painted.
I'm kinda bummed the helmet I made doesnt look exactly like the legendary edition. I may take the dremel to mine and cut the jaw off and lower it so there is more visor room. My helmet is a bit short.
I'll be back with more later on... along with randomly posting pictures.
-Cow