Greetings all!
I built a Boba Fett ESB costume back in 1998 the old fashioned way (raw plastic and a lot of mistakes!).   I pulled it out of the attic Halloween of 2009 to wear again, and the Don Post 96 Helmet that I had customized was completely warped out of shape.  I starting looking for a replacement.  Luckily for me, I am cheap, and that led me to Pepakura results, which led me to the 405th (yahoo searching).  I had NO IDEA people were making Halo armor.  I have been pepping ever since.  I currently have  MRK 6 and REACH armor in progress.