My Project MJOLNIR: Mk. VII armor + rubber undersuit

[armoryofalbus]

Hello 405th! Here’s my first post on here: a build thread documenting my build of Mk. VII MJOLNIR Armor. My build includes a rubber undersuit I made using Smooth On’s Dragon Skin 10 Fast. A lot of the pics in this thread come from my Instagram stories, where I have posted this build throughout months of sporadic work on it. Feel free to check that at “armoryofalbus” on insta

This past year I started reading the OG Halo books, and that inspired me to make my Spartan a solemn, no-nonsense green boi. (Secretly I just wanted to get called Master Chief at all the cons…NOT lol). I still probably love the Mk V B the most, but the Mk VII has some really cool elements to it and that’s what I opted for. Still drawing inspiration from Reach, my favorite game, I've gone for a Commando shoulder and Emile's small one (not sure its name atm) as my main shoulder parts. However I've also printed 4 other shoulders and plan to make them interchangeable (couldn't decide, LOL).

I completed the suit in May 2025. I began printing things near the end of December 2023. I took my time with this project and did not rush to get things done. No deadline really. So it was very satisfying to finally see it come together. Read on to see some of the steps I took to do this.

 

[armoryofalbus]

What launched this build was the gorgeous MK. VII resin print I was able to snag from Minutefett on Instagram. That print, paired with a hydrochromed branfuhr visor, was so encouraging and came out effortlessly- all I really had to do was carve out the visor area and drill some attachment points for the visor. I used epoxy putty to mount some Chicago screws into the helmet, and drilled some small holes into the edges of the visor. This allows me to remove it or swap as needed. I also incorporated a glowing blue light at the back of the helmet using some clear blue acrylic and some panel lights, the kind you see in Iron man helmets for the glowing eyes.

For painting this helmet I used various Rustoleum camo colors- a lighter one underneath, then dark. As soon as the dark green was laid down, I attacked the wet paint with a rolled up tape ball to get some organic paint chipping. Learned that technique from Island Fett on Instagram. I used his "tape ball" technique, plus some others, across all the armor to get the type of beat up paint chips I wanted. Silver chips with a molotow pen, sponged-on gray paint, some greens, and other weathering colors were applied topically across my armor, replicating the weathering I saw on the suits from the Halo show (the suits looked pretty good despite the show’s many disappointments).

Oh yeah- somewhere along the road, I printed Galactic Armory’s Mk V helmet and did my own chroming / dyeing effort on the visor. I wanted a helmet that I could swap out, to save my precious resin one from too much con abuse.

 

[armoryofalbus]

Most of my armor comes from files by Titlewavedesigns. At about the halfway point of this build, I saw the masterful work of datboibuilds and others who made rubber undersuits for their Noble Team, and I knew I had to try that. So I ended up printing the InstinctCreative MK VII rubber molds. While those rubber parts are intended for the Instinct creative armor files, they worked out just perfect with the titlewave armor. So no complaints at all with the titlewave pieces, and they printed great. I also love all the shoulder options titlewave offers. But if I were to do it all again, I’d go with the full instinctcreative set for uniformity.

Last year I was using an Ender 3 Max Neo, but once I got a Bambu P1S I completed the remaining half of my prints on that machine. Sanding was a breeze on most parts with very little clean up needed. I reinforced the chest parts with glue, then plastic welding, and finally fiberglass mats. I did the same reinforcing on my thigh parts, which printed in 3 pieces. The two halves of the chest come together on me using four parachute clips, which have similarly been locked in with resin. The clips are not the most tight join to bring the two halves together, and takes a bit of fiddling to get on, but I think I prefer that to magnets.

 

[armoryofalbus]

For the rubber undersuit, it was honestly pretty straightforward to make the parts: print the moulds, pour equal parts of each part of the Dragon skin, add some black acrylic ink, mix, and cast. I did ask many questions to others on Instagram before making my attempt at these parts though, and I learned a lot- happy to answer questions about this process. I started with the neck mold, cast a part— it was too short for my long neck and didn’t mesh with the helmet well (prolly cuz I’m 6’2” and skinny lol). So I reprinted that mold at a bit of a longer height along the Z axis, and it was perfect on my second cast!

As for wearing the rubber parts, that has been slightly more challenging. Basically each rubber piece is going to need some parachute webbing fused / embedded into it, so that you can clip in to the armor. (The only piece that didn’t need this was the elbows, they lock in nicely once you wiggle them on). Some of the rubber molds have intentional areas for you to thread webbing through a loop, but you still need to fuse them to the part first. I’m still learning as I go on these, and tackling the floating knee area is gonna take some fennangling as I try to get into the thigh/knee rubber combo.

 

[armoryofalbus]

A few months ago, my cousin wanted in on the action and he decided to print his own Spartan. He went for a security look from Halo four and five. Together, we cast two sets of rubber suits using about 2 gallons of dragon skin plus a few pints for touchup areas. His armor was slightly less complex than mine in terms of rigging, and by the end of a week working together, we were able to get his 95% of the way done. You’ll see some shots of his work sporadically throughout my pics. It’s a cool comparison to see a glossy black ONI operative type lad next to my beat up green boi

 

[armoryofalbus]

I also *think* I’ve landed on my loadout. LMG by Blazingforge on Instagram. Knife from galactic armory. Magnum found on Thingiverse. I got some 60lb weights and screw them to my thigh armor, they hold my magnum exceptionally well.

 

[Wing]

Looking great! loving those undersuits!

 

[armoryofalbus]

Looking great! loving those undersuits!

Thanks! They were super fun to learn how to make

 

[Crimson]

Holy smokes, it's not everyday that someone joins the server and then drops a build thread like this! I didn't know those printable molds existed and now I desperately need them XD

 

[armoryofalbus]

Holy smokes, it's not everyday that someone joins the server and then drops a build thread like this! I didn't know those printable molds existed and now I desperately need them XD

I've definitely been browsing the site for months now, but figured it was a good time to post my progress! Yeah, look for Instinctcreative on Etsy. Lots of amazing files! I'm unaware of anyone else that has done the full rubber undersuit for the Mk. VII. I would have loved to asked questions to someone who did my exact set of files from Instinct haha

 

[WatsonT]

Hello 405th! Here’s my first post on here: a build thread documenting my build of Mk. VII MJOLNIR Armor. My build includes a rubber undersuit I made using Smooth On’s Dragon Skin 10 Fast. A lot of the pics in this thread come from my Instagram stories, where I have posted this build throughout months of sporadic work on it. Feel free to check that at “armoryofalbus” on insta

This past year I started reading the OG Halo books, and that inspired me to make my Spartan a solemn, no-nonsense green boi. (Secretly I just wanted to get called Master Chief at all the cons…NOT lol). I still probably love the Mk V B the most, but the Mk VII has some really cool elements to it and that’s what I opted for. Still drawing inspiration from Reach, my favorite game, I've gone for a Commando shoulder and Emile's small one (not sure its name atm) as my main shoulder parts. However I've also printed 4 other shoulders and plan to make them interchangeable (couldn't decide, LOL).

As of April 2025, I still need rig the knees, calves, and do the boots. But I’m nearly there so I thought I’d do a post now (and procrastinate studying for finals). Read on for a bit more depth on what’s going on in the pictures!

View attachment 360559

Absolutely amazing work this sounds very similar to what I’m doing, but I’m only about a third of the way into the process, the only difference is I am using the under suit plans from tidal wave design, and re-modifying them to be molds. Anyway, looks fantastic.

 

[valyriel]

wow that looks great! the rubber undersuit looks super clean!
swappable shoulders is relatable cause I'm also indecisive

 

[armoryofalbus]

wow that looks great! the rubber undersuit looks super clean!
swappable shoulders is relatable cause I'm also indecisive

thank you! The rubber undersuit definitely compliments things. And yeah I can never decide if I want all green/black or some pop of bright color, hence all the shoulder options I'll be doing haha

 

[armoryofalbus]

Absolutely amazing work this sounds very similar to what I’m doing, but I’m only about a third of the way into the process, the only difference is I am using the under suit plans from tidal wave design, and re-modifying them to be molds. Anyway, looks fantastic.

Thank you! Definitely pleased with how it has turned out so far. And nice! I thought about doing something similar for some suit generations that don't have molds yet, but I don't have the 3D modeling skills haha

 

[Zippyzeek]

Holy smokes man! That's one of the best undersuits I've ever seen. How expensive was the molding process in general? I'm looking into doing some molding of my own. Looks awsome though and I'm excited to see what else you come up with. Welcome to the 405th!

 

[armoryofalbus]

Holy smokes man! That's one of the best undersuits I've ever seen. How expensive was the molding process in general? I'm looking into doing some molding of my own. Looks awsome though and I'm excited to see what else you come up with. Welcome to the 405th!

Thanks man! I didn't keep track of costs on this suit, but I estimate that the molding process cost about $350. About $280 for the Dragon Skin material ($200 for a gallon, plus some extra pints we got for backup / touchups) and then probably 3 spools of PLA to print the molds (they're somewhat thin with only 4% infill). But I've also sold a few neck pieces, so it's nice that once you have the molds you can recoup some costs

 

[billeybob250]

Where did you find the mods prints? that looks supper awsome.

 

[Unit287]

That looks so good! Where did you find the model for the LMG? Somewhere on instagram?

 

[armoryofalbus]

Where did you find the mods prints? that looks supper awsome.

Thanks! Do you mean molds? Titlewave designs on Etsy.

 

[armoryofalbus]

That looks so good! Where did you find the model for the LMG? Somewhere on instagram?

Thanks, I purchased the files for the LMG from Blazingforge on Instagram.