Christmas Exo-Armour Project - Pic Heavy - Completed!

[stateofdan]

Happy new year all!

So over Christmas and new year i thought a little simple project would be the order of the day. So i thought about doing an Aliens heavy lifter for my son would be the way forward.

While not strictly Halo, many of the techniques I used to construct the details have been learnt on here, so i thought I would share. In fact if it weren't for the 405th i doubt i would have thought about doing it!

The basic premise was to get a bunch of plumbing gear from the hardware store to build a frame and then use roof guttering to make the armoured parts. Then a bunch of trips to the pound shop to get lights and detailing etc. Foamies were used to add detail to the guttering to make it look more armoury. The total project was about £45 and has taken a few days due to managing kids and a cold

The back and overhead cage:
Using 1 1/4 in pipe and standard waste fitting I built the back frame and the overhead cage. I have used screws to keept he frame fix and a bit of MDF along the top of the back frame for better fixing properties for the arms.

Overhead cage is attached to the back frame up rights with a bolt to make a hinge

To make shoulder rests i used a bit of gutter made two cuts and then fired up the trusty old hot air gun! this stuff is surprisingly malleable and makes me wonder what parts of halo armour could be made out of it.

This worked pretty well, later i added foam inside and a foam collar for comfort, plus i had to add supports as the plastic gutter could not take the weight of the frame.

Forearm construction:
The forearms are straight gutter pieces, lined with foam and given a dowel handle:

After lots of consideration over complex claw like arrangements i went with something simpler. Using a short peice of 1 1/4" pipe, a bit of pipe lagging, dowels and cable ties I came up with this nice arrangement.

By pulling the cable ties the claws would close and the whole thing would fit nicely inside two bits of gutter to form a tube. A strap was added to keep it all in place.

Arms:
The upper arms were simply 1 1/4" pipe, more gutter, pipe insulation and dowel. The pipe insulation was inserted 1" into the pipes at each end and duck taped. to make the shoulder connections a dowel was inserted into the lagging and taped then screwed to the MDF bar across the back.

Guttering was added to the upper arms and across the back. you can also see I have mounted two head torches onto the overhead cage.

It was at this point i went a bit nuts and thought "you know what? This needs more details!" so out came the 5mm foamies and a considerable amount of time, effort and hot glue! But i think the details are worth it

Inner forearm vent:

outer forearm details:

upper arm details:

End of Part 1 due to picture limit

 

[stateofdan]

Part 2 here goes:


Leg construction:
Leg construction would follow the same pattern as the arms, gutter strapped to lower legs and then upper legs floating between that and the back frame. After cutting the gutter, i used a heat gun to flatten the bottom so i could attach it to the feet plates.

Pipes up the side add detail and a place for the joint. I used two blocks of 1 1/2" x 1 1/2" screwed and glued for the feet.

Strapping over the toe and around the calf managed to keep it all in place

Legs constructed and attached. Here you can also see the supports added to the should pads and the strapping to keep the back in place.

I only added detail to the upper thighs rather than lower legs as well.

Last touches and final result:
I wanted to wire up the head torches on the overhead cage so the could be switched on from one switch and since i had added details to the arms and legs the back looked left out. So inspired but the "how to build a cheap arc reactor" videos I used a lunch box, foam, two push lights and some plug hole covers to build a couple of exhaust ports and engine thing for the back

And here it is, back:

and front:

The final fitting:

Thanks for reading, your thoughts are welcome. I have learnt a lot from this project especially about other materials. I might think about making some HALO armour parts out of gutter as a test and post here. the combo of gutter and foamies was very effective.

 

[Verdan]

Dude, all my dad got me for Christmas was a list of jobs around the house!

Seriously though, good work. Are you planning to paint the pvc piping? I've never had much luck with it adhering when i've tried in the past.

 

[TheCaptainBacon]

That's a nice present for your son, he looked like he was enjoying wearing it in the photos. Are you planning to paint it? If you are, Plastidip works well to cover foam (and to an extent, PVC pipe), although it is a bit expensive.

 

[foxleader]

I'd say something but I think she says it better....

 

[jasonzed36]

coolest Christmas gift ever