My Project MJOLNIR: Mk. VII armor + rubber undersuit

[armoryofalbus]

I'm glad I stumbled across your thread. I'm remaking my Mrk V with Titlewavedesign files, and I bought InstinctCreative3D undersuit files but never got around to using them.

Nice, yeah the two can pair together really nicely

 

[PowerMaster MD]

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.
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My armour is blue and gold and I still git called "Master Chief"! Great undersuit.

 

[armoryofalbus]

My armour is blue and gold and I still git called "Master Chief"! Great undersuit.

lol, glad I’m not the only one. And thanks!

 

[PowerMaster MD]

lol, glad I’m not the only one. And thanks!

I wear a paint-ball vest with some added foam pieces. It gets pretty sweaty.

 

[armoryofalbus]

I wear a paint-ball vest with some added foam pieces. It gets pretty sweaty.

I’ve only worn it for 2 hours max so far, and the biggest thing for me was the weight, less the sweat. I’m hoping to wear this at Fan X in Utah next week so we will see how that goes.

 

[Bargo]

Your armor looks fantastic – especially the undersuit, it’s really awesome!


Now, my eagle eyes did spot something – I think your boot plate might be flipped. At least on the tongue piece, the files in the forum show the rounded, wider side facing down.

 

[armoryofalbus]

Your armor looks fantastic – especially the undersuit, it’s really awesome!


Now, my eagle eyes did spot something – I think your boot plate might be flipped. At least on the tongue piece, the files in the forum show the rounded, wider side facing down.

Thanks! Yep you’re right, I made a mistake while gluing the straps of that part on one of the boots and didn’t have time to correct it before this photoshoot lol. I always overengineer stuff and I didn’t have time to undo my glue + resin job. But good eye

 

[Fox3455]

That undersuit is stunning. Incredible work! Love the build thread. I need to step my undersuit up hard!

 

[armoryofalbus]

That undersuit is stunning. Incredible work! Love the build thread. I need to step my undersuit up hard!

Thanks! The undersuit definitely took some work but it’s very satisfying to see done!

 

[Fox3455]

Thanks! The undersuit definitely took some work but it’s very satisfying to see done!

It could not have turned out better! Now reap the reward!

 

[ArcaneGhoul]

How much Dragon Skin did you need for the ab wrap + the neck seal? I’m really not sure what material I want to use for mine so I’m trying to look at cost effectiveness currently. I’m stuck between TPU and Dragon Skin silicone, but am leaning towards the silicone because the look is just so slick.

Also did you coat the silicone in anything or is that the ‘raw’ look?

Thanks for the dope build thread, very cool to see and awesome to see so much written detail that I can learn from for my own suit building

 

[armoryofalbus]

How much Dragon Skin did you need for the ab wrap + the neck seal? I’m really not sure what material I want to use for mine so I’m trying to look at cost effectiveness currently. I’m stuck between TPU and Dragon Skin silicone, but am leaning towards the silicone because the look is just so slick.

Also did you coat the silicone in anything or is that the ‘raw’ look?

Thanks for the dope build thread, very cool to see and awesome to see so much written detail that I can learn from for my own suit building

For the neck seal it probably took about about 1/3 of a pint. I could make several neck seals from a $30 pint. As for the ab wrap/ torso, I would estimate that it took 1/4 of the gallon I bought, maybe a bit more. I was able to create all the parts from the gallon, plus about a full pint. I wish we kept a bit better track of material useage but we only had a few days to do the rubber parts and we were going fast. lol

 

[armoryofalbus]

For those curious here’s a few better shots of mine and my cousin’s Spartan together. By biggest area where I need to go back and fix are my knees- hard to create the “floating” knee by fusing into the rubber, and I get some inevitable sagging. Gotta work on that!

I don’t post much on here lol. But you can see more of his build at pjwdesignstudios on Instagram, and I’m at armoryofalbus on Instagram.

 

[BRVSTR]

I wish I'd stumbled onto this thread much earlier, lol. I just bought some Dragonskin 10 myself - that, the dye, and thickening agent just came in. I just bought four of the pint set to handle the shoulders and neck seal for now.

Your build is absolutely gorgeous. You weathered it so beautifully and the undersuit just seals the deal! It's such a simple, understated look that packs a huge punch.

 

[Spiderboy196]

For those curious here’s a few better shots of mine and my cousin’s Spartan together. By biggest area where I need to go back and fix are my knees- hard to create the “floating” knee by fusing into the rubber, and I get some inevitable sagging. Gotta work on that!

I don’t post much on here lol. But you can see more of his build at pjwdesignstudios on Instagram, and I’m at armoryofalbus on Instagram.
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Nice h5 security

 

[sir howard]

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.

idk how people do the undersuit. my crack sweats sitting against a fan in the AC in winter. Id smell like hotdog water ahahha

 

[ArcaneGhoul]

For the neck seal it probably took about about 1/3 of a pint. I could make several neck seals from a $30 pint. As for the ab wrap/ torso, I would estimate that it took 1/4 of the gallon I bought, maybe a bit more. I was able to create all the parts from the gallon, plus about a full pint. I wish we kept a bit better track of material useage but we only had a few days to do the rubber parts and we were going fast. lol

Good to know! Thank you! I’ve got to model my own mold as I want to use the neck seal file that came with my TitlewaveDesigns MKVII suit, but I bet it should be about the same amount used. I’ve seen so many great builds lately with silicone parts that think I’m just going to go for it and make the neck seal. I’d love to do the ab wrap/undersuit too, but I can’t really stomach the $200+ price tag for a gallon of Dragon skin at the moment, so it may not be in my near future to do anything other than the neck seal, but we’ll see.

Do you have any specific tips or tricks for the making the neck seal? You’ve made a great write up for your suit but would love to know any extra details that you’ve got.

 

[armoryofalbus]

Good to know! Thank you! I’ve got to model my own mold as I want to use the neck seal file that came with my TitlewaveDesigns MKVII suit, but I bet it should be about the same amount used. I’ve seen so many great builds lately with silicone parts that think I’m just going to go for it and make the neck seal. I’d love to do the ab wrap/undersuit too, but I can’t really stomach the $200+ price tag for a gallon of Dragon skin at the moment, so it may not be in my near future to do anything other than the neck seal, but we’ll see.

Do you have any specific tips or tricks for the making the neck seal? You’ve made a great write up for your suit but would love to know any extra details that you’ve got.

I would definitely get a pint of the material for around $30 and go from there. You could probably make several neck seals from that pint. I think from my initial pint, I made two neck seals as well as the inner rubber part of the thigh armor. My only other tips for making the next seal would be to make sure it’s going to fit your neck. I printed one neck mold, using the fuzzy skin feature in my slicer, and I did not like how it came out. It was too short (too much skin showing) and I didn’t like how the fuzzy skin looked. So after that I reprinted the neck mold and stretched it vertically in Bambu slicer by about 2 1/2 inches, so that the rubber met right underneath my chin. I also learned from doing that initial mold that I wanted all of the molds to be smooth with just filler primer to smooth them out. I did not use any truck bed liner or anything that you may see others using

 

[ArcaneGhoul]

I would definitely get a pint of the material for around $30 and go from there. You could probably make several neck seals from that pint. I think from my initial pint, I made two neck seals as well as the inner rubber part of the thigh armor. My only other tips for making the next seal would be to make sure it’s going to fit your neck. I printed one neck mold, using the fuzzy skin feature in my slicer, and I did not like how it came out. It was too short (too much skin showing) and I didn’t like how the fuzzy skin looked. So after that I reprinted the neck mold and stretched it vertically in Bambu slicer by about 2 1/2 inches, so that the rubber met right underneath my chin. I also learned from doing that initial mold that I wanted all of the molds to be smooth with just filler primer to smooth them out. I did not use any truck bed liner or anything that you may see others using

Brilliant thank you! I just ordered a quart and it’ll be here later this week. I really appreciate all the tips and suggestions

 

[JTF4]

Amazing job on getting that under suit done. I love the look of a proper cast under suit. Gets pretty hot, but totally worth it.

For the floating knee, it might be worth looking at making an elastic cuff, and then anchoring it to the back side of the knee part just slightly above the center of the knee. If you do that, it'll leave the rest of the knee seal to move around, but keep the knee armor anchored in about the same spot. It'll be a bit annoying to put on until you get it figured out, but I think it would help with the knee wanting to fall down.