So I’ve been wanting to make Halo 2 Marine armor. And since it’s not as complicated as other sets, I thought I’d be really cool to make it out of metal. Has anyone here made armor out of metal before? Any tips, tricks?
I've made a metal helmet too. I traced out pep templates on steel, cut them out and welded them together. You can smooth it out a bit with a hammer, but unless you do a lot of forming, you'll have some edges, but they're not too noticable. For tools I'd recommend at least a fluxcore welder, an angle grinder, tin snips and some hammers.
Casting aluminium would be quite heavy too. I made my helmet from 0.75mm steel and after grinding, it came out to 2.5kg, which is heavy, but still wearable. Aluminium is about 2.5 times lighter, so unless you can cast it 2mm thick, it would be heavier. Aluminium would allow you to use thicker material though so you can grind it more before making a hole. I chose steel because I can't weld aluminium, but it depends on the tools you have.
Casting sheet does sound tough. Casting might work for some parts but not all of them. I found this video about connecting aluminum with a brazing rod. Personally, I would try applying an EVA template to aluminum sheets and go from there.