Halo 4 Master Chief High Detail Resin & Bondo Build WIP (pic heavy)

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When it comes to the undersuit, try using a couple of layers of 2mm EVA craft foam and making an "iron man" style suit to wear over the undersuit. If you black plasti-dip it, it will look leather-like. You can detail it well enough and if a piece rips, just replace it.

I was planning on doing something to that effect after all the hard armor was completed. Was toying with the idea of buying a skin tight, full body spandex suit off Ebay for around $20 and using that as a base to attach some EVA, foam padding, vinal or what ever I decide to use for under armor detail.
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I really like the idea of having only one piece of soft armor/fabric to put on. Also don't have to worry about any skin showing through like around the neck.
I speak from personal experiance.
:(

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The Genius And Ruin Of My Boot .

When I started my new Halo 4 suit, I set out to improve upon the design of my original. There are many problems with my first suit when it comes to functionality. For instance, the boots are a two piece unit that must be put on separately, then fit together once on the foot. It works ok for wearing and walking but is a real pain to put on.

I wanted to fix this problem with my new build by making the boot a one piece that can be put on without any real issues or work. This was my solution.

The toe piece is attached to the base with a hinge allowing it to swing forward, exposing the shoe and allowing plenty of room to get your foot in the shoe.

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The hinge is mounted to a piece of PVC plastic sheet cut out to act as a frame and base for the armor pieces to sit upon.

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After your foot is straped into the shoe, the toe armor is simply moved back into place, completely covering the front of the shoe. The toe armor is held into place by two powerful 40lb pull force neodynium magnets, one on each side, that pull against a thick steal plate embeded in the other side of the PVC frame.

The magnet is actually an inch long. The rest is installed into the armor itself to make sure it doesn't come loose.

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The steel plate on the back side of the frame.

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If you ask me, the idea is quite brilliant! I personally have never seen this exact design used before on a boot piece. Unfortunately, there is a great flaw with my design.:(

Despite there being an estimated 80lbs of force pulling the magnets against the PVC frame, the toe piece still comes loose when my foot bends while I walk. After my foot straightens out, the piece will snap back into place because of the pull of the magnets. So it’s not like the whole toe comes flopping forward after a few steps. It does make a loud clapping sound from the magnets jumping back into place.

Also due to the design the boot is very heavy and has little to no bend which makes walking very cumbersome and awkward. At the present I have only one boot finished. I plan on designing the other boot in a completely new way that will better improve comfort and mobility as opposed to dressing convenience. If I succeed, I will modify the current boot pictured above in the new design.

In hind sight, I may have made the pep pieces for the boot too small. As a result, my foot does not have much room in the toe area leading all the way to the top of my foot. So when I walk the boot is to tight and aids in the magnets breaking their hold.



Shoot of boot bottem. Frame and foam layers actually sit around shoe, so shoe's bottem is touching the ground. This allows the armor pieces to sit a bit higher on shoe and gives my foot more room. But not enough Im afraid.
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