TisonB
New Member
The following post details my process over the past five years building my hand made Eva foam master chief suit. This is where I started, what I learned, and what I overcame.
Arguably the most important piece of this puzzle is the helmet, so it only made sense to start there.
The one piece here that’s not foam and for good reason. I acquired the legendary edition helmet 5 years ago and disassembled it to put together a wearable helmet.
This was five years ago back when I was in high school and I’ve hit the gym since this picture. Put on around 30 pounds of muscle. But that’s a tutorial for another day.
Immediately after I moved onto building a shin piece from pepakura, and within a day the entire thing fell apart. That was it; the end of the story for a while. Until..
Flash forward to 2024 where this project had been lingering in my mind like an itch you just can’t reach. It’s been my dream since I was a child to build my own mark 6 armor set and deep down I still wanted to prove to myself that it wasn’t impossible. That I was capable of building it. So, I simply moved on to the next piece like no time had passed. I had gotten better at building from foam, so maybe things will be different.
And I’ll be darned, I was actually pleased with how it was looking. Maybe I CAN do this.
Around this time something else happened too. After taking 3D design courses in college I realized I could more than likely pattern the pieces now myself. So that’s what I started doing and from here on out every piece is patterned by me.
The mark 6 used to look impossible to me as if it posses infinite detail. However, with a trained eye I began to break each piece into simple shapes focusing on finding the correct angles and curves.
Later on I eventually re made the biceps to be more proportionate. In design classes you learn about visual weight and these pieces were a little too ‘heavy.’ More on that later.
By the time I had reached the gauntlets I began to feel confident in my process. That being create the basic form, and then fill in the details with thin foam until you reach the proper silhouette.
And something important to note- because I knew I would be wearing a padded undersuit I added around a quarter of an inch of room to every piece.
By this point it’s July 2025 and I’m finally working on everything consistently in my free time. The more I complete the more motivated I get to cross the finish line.
The last pieces I completed were the boots and it was ready to paint just in time for fan boy exp!
Everything was coated in plasti dip and then automotive filler primer.
And now for my favorite part, the green. It took me awhile to decide on which green I wanted but I found something that was close to the halo 3 in game model
I took the suit as it was to the con and had a wonderful time, but work was still left to be done.
I made an undersuit ab wrap out of 2mm foam based on the infinite suit.
All that was left after this was some extra weathering, fitting, and re making the biceps like I previously mentioned. Mostly to be more accurate to the infinite armor and to take some weight off the arms.
And just like that five years all passed by in the blink of an eye. I ultimately did this to prove to myself I could do it. Yes I have not crossed any new ground here and everything I did here so many others have perfected already. But this was a true passion project and I’m happy that I finished this fight.
The final suit.
Arguably the most important piece of this puzzle is the helmet, so it only made sense to start there.
The one piece here that’s not foam and for good reason. I acquired the legendary edition helmet 5 years ago and disassembled it to put together a wearable helmet.
This was five years ago back when I was in high school and I’ve hit the gym since this picture. Put on around 30 pounds of muscle. But that’s a tutorial for another day.
Immediately after I moved onto building a shin piece from pepakura, and within a day the entire thing fell apart. That was it; the end of the story for a while. Until..
Flash forward to 2024 where this project had been lingering in my mind like an itch you just can’t reach. It’s been my dream since I was a child to build my own mark 6 armor set and deep down I still wanted to prove to myself that it wasn’t impossible. That I was capable of building it. So, I simply moved on to the next piece like no time had passed. I had gotten better at building from foam, so maybe things will be different.
And I’ll be darned, I was actually pleased with how it was looking. Maybe I CAN do this.
Around this time something else happened too. After taking 3D design courses in college I realized I could more than likely pattern the pieces now myself. So that’s what I started doing and from here on out every piece is patterned by me.
The mark 6 used to look impossible to me as if it posses infinite detail. However, with a trained eye I began to break each piece into simple shapes focusing on finding the correct angles and curves.
Later on I eventually re made the biceps to be more proportionate. In design classes you learn about visual weight and these pieces were a little too ‘heavy.’ More on that later.
By the time I had reached the gauntlets I began to feel confident in my process. That being create the basic form, and then fill in the details with thin foam until you reach the proper silhouette.
And something important to note- because I knew I would be wearing a padded undersuit I added around a quarter of an inch of room to every piece.
By this point it’s July 2025 and I’m finally working on everything consistently in my free time. The more I complete the more motivated I get to cross the finish line.
The last pieces I completed were the boots and it was ready to paint just in time for fan boy exp!
Everything was coated in plasti dip and then automotive filler primer.
And now for my favorite part, the green. It took me awhile to decide on which green I wanted but I found something that was close to the halo 3 in game model
I took the suit as it was to the con and had a wonderful time, but work was still left to be done.
I made an undersuit ab wrap out of 2mm foam based on the infinite suit.
All that was left after this was some extra weathering, fitting, and re making the biceps like I previously mentioned. Mostly to be more accurate to the infinite armor and to take some weight off the arms.
And just like that five years all passed by in the blink of an eye. I ultimately did this to prove to myself I could do it. Yes I have not crossed any new ground here and everything I did here so many others have perfected already. But this was a true passion project and I’m happy that I finished this fight.
The final suit.
