My Hayabusa Armor Progress


Active Member
After a cold, snow filled winter, I have some progress. Handplates and shoulders are hardening with some smoothcast 320, biceps and forearms are constructed Bevbor style out of cardboard cut from pep pieces, and the Hayabusa chest piece is pepped and sitting in place ready to be resined.

Pictures of progress

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Active Member
Bungie day update: lots of pictures. Thanks goes to Ithica for the flex foam-it lower body. Arms and chest perm were all hardened and smoothed using smoothcast 320.

Lower body almost done, boots need to be connected since I have big feet and had to cut them, and need to attach the straps to the thighs to connect to the belt.

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Helmet needs to be repainted in a darker blue to match other painted parts, and final details were added. Visor is cut and ready to be glued in, electronics and padding is ready to be installed.

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Chest, back, and perm are smoothed and ready for painting and mode of being attached.


Arms need to be painted. The forearms and handplates need black detail painted on, shoulders are smoothed and ready for painted, hayabusa shoulder almost done, and eod shoulder still being detailed.

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More will be added when taken.

LongShot X

Well-Known Member
AWESOME JOB so far! Keep posting your pics. Very inspirational!

Cheers! :)


New Member
Not only is the modeling of your Hayabusa armor quality grade, but the painting is awesome. Seriously, I am considering doing my Mark VI in blue now. Then that black detailing is just spot on. Nice work. Continue at this rate with the rest of your suit and you will definately have an amazing suit of armor in the end.


Active Member
I have run into a bit of a problem, while test fitting my armor the back neck piece of my helmet hits on the back plate on the raised piece. Since that is the problem i will have to cut that piece off to allow me to have more motion in my neck. I wasn't sure if anyone else building a hayabusa helmet has run into that problem, if so what were your solutions?


Active Member
Armor is 99% done and I will post pictures later, just need some help asap. What is the best way to mount a visor, and what type of glue/method works best? I am very short on time and need to know cause the con I am going to is this weekend.

Edit 7/26:


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Any updates on the armor that happen will be posted tomorrow or after Otakon.

soul products

Well-Known Member
for the visor, i suggest glueing a piece of black foam inbetween the helmet and visor itself. id say no more than 1/4 in thick piece. it gives a really clean finish to the helmet.


Active Member
Just got back from Otakon 2010, and I have some full costume photos to show.

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Master Chief, didn't get your name but your costume was great.