Active Member
It has been quite some time since I last posted anything here. Even longer since I showed any progress toward anything. But right now I'm going to do my best once more to compile and show my logs and data of what I'm doing to build my next ODST suit. This time I'm going for the one in the Halo 4 game. Haven't seen much love for this type of armor.
Not to mention that since I built it last time it was fragile and weak as can be. But this front torso piece not only has some actual weight to it but is also sturdy as a rock. MUCH better than my MKII. Here's what I got so far for the rest of the suit:
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For the overall concept:
Since armor builds like this require a lot of space to pack and transport, I've decided to try and break this build into several different parts:

- Front Torso.
- Shoulder Straps.
- Side Straps.
- Back Torso.

The collar that is usually worn by them WILL be an optional thing to include. Though and AM doing some planning to implement it for the build. Maybe I'll separate it into half's: one for the front, one for the back, and create a locking device for them to meet at the sides. As for the build so far, it's going along super smoothly. Kinda wishing that the chest piece was a bit smaller so I can reach my arm forward but I've noticed this problem with any cosplayer who does an ODST build, so I'm not alone there.
I've made the shoulder strap solid because I'll be covering it in a fabric of sorts and gluing on a black nylon strap to the top. Make it a bit more authentic. The white strips you see along the shoulder strap is of 5mm foam I got from Hobby Lobby. I've noticed that in most builds that these are crucial and VERY important in understanding the placement of a part. Especially if they have an edge ID on them.
So I cut them in 5mm strips for that spacial purpose. I cut the larger pieces in an inward cut so the strips can be easily cut and glued on since they were very small. I DID mess up on the buckle placement on the shoulder placement and strap though.

I didn't have enough surface space to place the shoulder strap on and only had the cut edges. If I had continued with this then the shoulder area would've been weak to withstand the tension. So I cut out a piece of scrap foam that would be covered by the strap and glued on the extra surface. This made it much easier to plan on more ways for the strap to not only use the buckle to be attached, but also use other means for a more secure placement.
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The buckle placement on the strap was another failure but was recovered with quick thinking. I honestly thought that two buckles would do the job for a more secure fit but failed to realize that there would be no room for my fingers to detach them. So I had to use scrap foam and reglue the sides. And instead only hot glued one buckle instead of two.
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Note: I used a LOT more hot glue to make sure this piece was not going anywhere.

I'll post more pics of the what I'm aiming to achieve, what my plans are, and how the progress is going in the future.


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Sr Member
Member DIN
yyyyeeeeeesssssss, wisconsin homie back on the grind!! you gonna get this done in time for collasal north? (previously daisho con in wisconsin dells)


Active Member
yyyyeeeeeesssssss, wisconsin homie back on the grind!! you gonna get this done in time for collasal north? (previously daisho con in wisconsin dells)
Oof, that's a negative on that front. I've got plans upon plans on making this be able to break down for easy transportation. Which means more time to draw out plans, test and apply. Not to mention I want this to look more clean and detailed than my MKII. Not to mention life kinda getting in the way with my job's hours and several other hobbies on my mind. It gets kinda busy. Lol


Active Member
Nice build so far. I'm brand new and thinking about doing an ODST myself. Where'd you get the foam files for yours?
I got mine in the 405th's armory in the "Halo 4" section. I just had to mess around with the file a bit to have it be shaped to my size in both "Armorsmith" and "Pepakura."


Active Member
Got more progress done to the shoulder straps and the back piece over the past few days.
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Next I'm going to attach 2mm over the back to cover the large gaps. Near the bottom of the piece I'll counter sink some magnets so I can lift up the flaps and detach the shoulders and leave the middle piece glued on. As for the middle piece, I'll use some Velcro and make it detachable as well since it very close to the buckle's gap, leading it to cause some tearing if I were to open the flap. Will show the plans later in the following days.


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Active Member
Got some more building done to the back piece. The black piece is made of 2mm foam that is PARTIALLY glued. Only the middle is permanently stuck together. The end pieces are left open to add on magnetics, leaving an access to the buckles.

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The back piece was made by a template from scratch just like the 2mm foam, but this still held onto larger foams thickness. I originally thought this piece to become removable for more of an easy access with the flaps. But after the testing, it turns out this piece didn't impair that action. So I just glued it on.
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The suit so far.

The original plans.


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Active Member
Much progress has been done last week. Managed to get the side pieces all nestled and glued onto the back. And it's holds up pretty well! Yeah it may look a bit like an open wound with the buckle there. But I put some 5mm foam on top of it to make it more like it belongs there. Just need to round it off and make it more like a futuristic piece of armor.

Edit: For Pic.3 I DID add a TON of hot glue to make sure that piece didn't have a CHANCE of moving out. Just wanted to make that clear.
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Active Member
Oh boy, we got some problems here. Biggest being the side straps. Apparently, with the hot gorilla glue, alongside with the buckles, has made the connection area VERY stiff. The torso WILL NOT BEND a great deal, if at all. This what I want, no? Eh, Kinda. The area of connection is so stiff that the flow does not go smoothly from front to back.
Instead it just kinda... bows out. Making the straps go wider and not fitting correctly. Second is the buckles. Thought I'd get smart and figure "Hey, this will lighten the tension being put onto one buckle for the front!" What I didn't take into consideration was the fact that... These parachute clips are VERY VERY sturdy when connected! It takes a great deal of finagling to get them BOTH unlocked at the same time since they push away from each other during the process.
And if basic logic is coming back to me, if you have a sturdy locking system that pushes away from each other, it's gonna be real difficult if you have another in the same area and locked near the other. I'm sure I'll get this problem fixed in a day or two. So I'm going to spend one weekend trying to revert this back while focusing on the shoulder straps on weekdays. I'll update more as it comes.
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Active Member
This was weekend was a good workday! Not only have I managed to build a locking system for the shoulder straps, but I also managed to fix a bit of the sizing issue as well! For the shoulders, I used center button clips instead of the parachute ones and the results were... mixed. What I mean is that even though I can easily put on and take off the straps while wearing it, the process of detachment is a bit more finicky to separate. Not in terms of double clip sense because even then I can separate those more easily.
What I'm saying is that to separate the center button clips I have to ACTUALLY wear the piece. I think it has to do with the weight of the armor helping the entire process and making it slide off more smoothly than doing it on the ground. Either way these things ARE helpful, but I STILL feel as though the parachute clips work in a more simple sense. The black foam you see is for more of a structural integrity of the straps and front torso piece and more material to glue the clips on. The slab of foam under the "female clip" is there to not only decrease the time of guessing where the connection is, but also structural integrity so the clips and foam don't bend out of whack.
And the hole in the shoulder straps is to accompany the foam slab.
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As for the side Straps, I cut the pieces after marking where it would feel tighter and hold onto the body as well where the clips would reach. After that, it was only a matter of cutting them out and gluing to make shorter. All's of this would be mostly covered with some 2mm foam when I start to add details. It fits more snuggly but I STILL want to shorten it because I still feel them touching my arms. And if they touch my arms, what are they gonna do when I add my bicep armor, or my gauntlets for that matter?
More research needs to be done on this. I STILL regret having to put on 2 clips on the sides; one would've been enough. But lesson learned for my MKIV.

Here are the pieces disassembled, reassembled, and me wearing it. All in all, a good discovery for my skills.
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Active Member
No updates this week, I'm afraid. Been busy with an event that came up and life's been keeping steady at my heels for the past week. Might even be for a couple, but I'll post an update here and there when I can on weekends to show that I AM still doing this build. Need a Halo suit and this is the only way to do it.
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