Halo The TV Series Master Chief full build
- Thread starter Nimitz
- Start date
Nimitz
Member
Decided to change directions slightly WRT boot armor .... it dawned on me that since teh only part of the boot armor that flexes is at the toe cap that I could mold the entire boot as 2 pieces making it a lot easier to assemble & stay together ... so I put the 3 armor pieces together and then remolded it and did another flexible resin casting and it turned out great ... I also cast the hand armor in flexible resin as well
After I cast the second boot I'll start working on a secure attachment method ...
Nimitz
Member
Ok, I finished attaching the toe caps to the rest of the armor so it was time for the first real litmus test to see if I was as clever as I think I am ... so I got out my boots, put on the boot armor and tried walking around ...
And while I didn't exactly wear them for several hrs they do appear to function as I planned ... they cover my boots, don't require any type of attachment to my boots, the 2 parts stay together and most importantly I can walk normally in them ... and they are simple to put on. The boots I'm using have zippered sides so basically I just slip the boot armor over the boot, pull the tongue up, slip my foot in and zipper it up. Takes all of about 5 secs, which is in stark contrast to my Mando boots which take about 5 mins per boot to put on .
So I've now primed each of them and set them aside along with the other armor pieces I've finished and are ready to paint.
Today I also finally managed to get my duct tape dummy made, at least the hard part of getting wrapped up in duct tape for 2 hrs and then getting cut out of the 'suit'.
I'll post some pics once I get the pvc frame built and the mannequin gets stuffed with old plastic bags, re tapped and installed on the frame, it's going to be a game changer for completing the undersuit and completing the armor attachment harness system. Unfortunately (or maybe fortunately) we forget to get some pics of me all wrapped up ...
And while I didn't exactly wear them for several hrs they do appear to function as I planned ... they cover my boots, don't require any type of attachment to my boots, the 2 parts stay together and most importantly I can walk normally in them ... and they are simple to put on. The boots I'm using have zippered sides so basically I just slip the boot armor over the boot, pull the tongue up, slip my foot in and zipper it up. Takes all of about 5 secs, which is in stark contrast to my Mando boots which take about 5 mins per boot to put on .
So I've now primed each of them and set them aside along with the other armor pieces I've finished and are ready to paint.
Today I also finally managed to get my duct tape dummy made, at least the hard part of getting wrapped up in duct tape for 2 hrs and then getting cut out of the 'suit'.
I'll post some pics once I get the pvc frame built and the mannequin gets stuffed with old plastic bags, re tapped and installed on the frame, it's going to be a game changer for completing the undersuit and completing the armor attachment harness system. Unfortunately (or maybe fortunately) we forget to get some pics of me all wrapped up ...
Nimitz
Member
Well I finally managed to get my duct tape dummy completed so here are a few lessons for anyone getting ready to do this
1. You only really need about 3 rolls of duct tape. I watched a bunch of videos and they all talked about 6-10 rolls. Not sure what they were doing but you don't need anywhere near that much. I'm 6' 185lbs so not exactly small.
2. Go on TEMU and buy a set of long sleeve Lycra stretch top and bottoms, they cost about $10. Don't go the 'painter's body suit' route as that requires you to cut the suit while you're taping to ensure a body tight fit and ends up being a bunch of extra work for no added value
3. Make sure you have set of EMT scissors which are specifically designed to cut people out of clothing
4. Taping should go in this order: ankles and wrists first, shoulders and crotch next, then abdomen, butt and upper thighs, then arms then legs
5. Before making any cuts draw a line with a Sharpie from the back of the ankle to the back of the knee, from the wrist to the elbow and from the neck down to the waist. At about every 3" draw a line perpenducliar to your cut line. This is critical so that when you tape him back together you don't change the shape
6. When you get cut out of the duct tape you will be naked so plan accordingly
The arms look a little funny in these pic because I had not yet stuffed them with anything
1. You only really need about 3 rolls of duct tape. I watched a bunch of videos and they all talked about 6-10 rolls. Not sure what they were doing but you don't need anywhere near that much. I'm 6' 185lbs so not exactly small.
2. Go on TEMU and buy a set of long sleeve Lycra stretch top and bottoms, they cost about $10. Don't go the 'painter's body suit' route as that requires you to cut the suit while you're taping to ensure a body tight fit and ends up being a bunch of extra work for no added value
3. Make sure you have set of EMT scissors which are specifically designed to cut people out of clothing
4. Taping should go in this order: ankles and wrists first, shoulders and crotch next, then abdomen, butt and upper thighs, then arms then legs
5. Before making any cuts draw a line with a Sharpie from the back of the ankle to the back of the knee, from the wrist to the elbow and from the neck down to the waist. At about every 3" draw a line perpenducliar to your cut line. This is critical so that when you tape him back together you don't change the shape
6. When you get cut out of the duct tape you will be naked so plan accordingly
The arms look a little funny in these pic because I had not yet stuffed them with anything
Nimitz
Member
Got on the sewing machine today and completed altering the vest that will be used to attach the abdomen, side and back undersuit pieces. Also, I'm not going to add any ribbing at the shoulders now that I can see how everything is fitting there really won't be anything showing as the gap is quite small.
Next up is to layout the laser cut foam pieces for the abdomen and mark out where the side panel ribbing will go to line up with the side panel ribs I've already made for the pants at which point I can just sew the ribbing directly onto the vest and hopefully just use contact cement to mount the foam ab panels ...
Next up is to layout the laser cut foam pieces for the abdomen and mark out where the side panel ribbing will go to line up with the side panel ribs I've already made for the pants at which point I can just sew the ribbing directly onto the vest and hopefully just use contact cement to mount the foam ab panels ...
Fuerteventura
New Member
Good evening, I'm looking for ways to install the head support inside the helmets... so that the system works for any model.
Thank you very much.
Thank you very much.
SgtSaint
Well-Known Member
- Member DIN
- S027
you should create a thread for help for your project then - not hijack someone else's build thread
KaeSpoon
Active Member
- Member DIN
- S226
It costs nothing to be kind; so let us remember to be kind to others, even if they aren't posting in the right place.
Hello Fueteventura,
Unfortunately, making a modular system like that is going to be difficult to make as a universal fit. Everyone has different-sized heads; someone like myself has a 21.5-inch head, while others have 23+ inch, and each individual helmet from Halo fits a little differently. Most of us make our own custom padding in our helmets, let it be EVA, or removable helmet padding made for helmets like motorcycles.
If you would like additional support, I would recommend our tutorial section or making your own thread.
I love seeing folks use the duct tape dummy method in 2025. This has saved me so many times! I'll keep my eye out for future updates, and I cannot wait to see how this built turns out.
Kind regards,
Fuerteventura
New Member
Thank you very much, and my apologies.... This is the first time I'm using this platform and I didn't know where to do it.
And yes, it doesn't cost anything to have a little empathy for others; nobody is born knowing everything.
And yes, it doesn't cost anything to have a little empathy for others; nobody is born knowing everything.
SgtSaint
Well-Known Member
- Member DIN
- S027
Nothing unkind or unempathetic was said. Nobody was name called or insulted... no rude remarks about his lineage or his dog... nothing mean about him as a person. Just a simple remark about common 'nettiquette. Nothing more. There's no need to make more of it than that. No need to assign characteristics to my comment that aren't there. If you don't imagine lines that aren't there, you don't have to read between them. If you just take the text at face value, as written there's nothing for you to get defensive about.
Brother Drim
Member
- Member DIN
- S706
I love what you are doing with the undersuit portions of this suit. As someone who melts in a silicone undersuit, this really inspires me to go a different direction with my next! What did you use for the piping material? If you posted it in an earlier post and I missed it I apologize.
Nimitz
Member
Nimitz
Member
For sure. On just this vest alone it saved me a bunch of time that would have otherwise been wasted trying to measure and alter this while i was wearing it. The ability o just alter a piece while "you" are wearing it so you know it will fit correctly is amazing!
Nimitz
Member
Exactly! While researching this build my first cunning plan was to build a silicon undersuit. Luckily for me I couldn't really find undersuit files in order to make molds and do the casting etc. then as my research continued I stumbled onto information from the prop dept on exactly how his undersuit was made for the show and discovered it was 3 pieces: long sleeve top, 3/4 length bicycle pants and a vest, and that they were all sewn! They made my decision easy and I pivoted to making a sewn undersuit.
Given how much work (and cost!) just casting the boots in a flexible resin was I'm REALLY glad i didn't pursue silicon. Also, given I just finished a Cooper Howard The Goul costume which sported a full head Platinum silicon mask I was very familiar with wearing silicon for long periods of time
The piping material is just 8mm soft cotton rope found on Amazon. When you cut it to length just wrap the ends with a small piece of painters tape so they dont fray on you hide sewing. I also bought some 4mm for the neck piece but for the arms it requires a Larger diameter to stand out.
