One popular method and a method that I use myself is to create the abdomen section out of eva foam, warp certain parts in faux leather, and then sew those pieces together. It will create a really slick under suit between your torso armour and your waist armour. Below are some links to different methods for making the under suit.
N8TEBB's Under-Suit Help Directory
Here's how I made my mk VII ab wrap:
I want to make a mk 7 suit this summer. I'm going in with a bit of a plan but really I plan on making it up as I go along. This is what I want my spartan to look like when all is said and done: I think the shoulders will be different, maybe the handplates, and different paint job on the gun...
www.405th.com
Here's a helpful thread to see how folks made their under suits:
The 2nd entry in the hit series "What's your _____" is What's Your Undersuit? Plenty of people are asking so throw a picture of your costume, what you used and link (please be sure to embed it in text so it does not fill the page) I'll make a sample to show it off! Costume: clothing used...
www.405th.com
And here's links to other folks posts about how they made their under suits:
Helmet's all wired now! Got 2 individually controlled fans and the wireless mic all hooked up :) Stashed a spare battery in my thigh... just in case.
www.405th.com
So finally the time has come where I show my process of making my Reach undersuit!! First and foremost, I want to give initial credit to WandererTJ , Because He is the one who made the pepakura model of the undersuit that I used to make my patterns, and KitKatGoose , Who I originally got the...
www.405th.com
In depth tutorial for undersuit on page 9 Finished suit
www.405th.com
Hey everyone! This will be where I post progress and details of my new Reach suit. I've created two Reach suits in the past, one for myself and one for a friend. Hopefully this one will be even better looking and better functioning. This suit will be pretty much all foam, made with pep patterns...
www.405th.com
indeed they are! but i am a lowly noob in this fine craft
www.405th.com
So I started doing an unfold for the Mk 7 undersuit and intended for it to be a prototype… never intended to start a new build but you guys know how that always turns out. I am using TNT 4mm foam for these pieces. I built this with flexibility in mind. Each panel has nylon webbing between...
www.405th.com
Hey everyone, I'm Mitch I'm an Australian cosplayer who got into cosplaying specifically to make a Halo 3 Master Chief costume a few years ago. Back then I decided to make a clone trooper costume at the last second as I had no previous 3d printing, painting or general costume-making experience...
www.405th.com
