WIP - Bargo - MKVII - EVA Built

[Bargo]

Hello everyone,


You can call me Bargo. I'm a cosplayer from Germany and a proud member of the Mandalorian Roughnecks. I've been part of the cosplay scene for many years now, and it all started with the idea of building my own Halo armor.


Back then, I tried to make a helmet using Pepakura, but my attempts always failed – the helmets were always too small. At one event, I saw some Mandalorians and thought, “That looks a lot easier.” And just like that, I spent the next 10 years exclusively building and wearing Mandalorian armor.


Now, after a full decade, I’ve decided to go back to my roots and finally build that Halo armor I originally dreamed of. With all the knowledge and skills I’ve gathered over the years, I feel ready to create a suit that I’ll love – and hopefully others will too.


Instead of going the usual 3D printing route, I really wanted to build the entire suit (except the helmet) out of EVA foam, making it as comfortable and flexible as possible. This is my first EVA armor build, and so far, it's been going surprisingly well!


Thanks to this forum, I was able to create a Blender render of my Spartan.

The armor I’m building is a Mark VII Spartan armor, featuring:

• Grenadier helmet
• ODST shoulder pieces
• A UA Relic Plate chest attachment
• A thigh pouch
• And as a unique addition: a half kama

The kama will be worn on the right side, hanging under the belt, reaching from the belt down to the knee. It will cover the rear, ending at a slanted angle at the back. The fabric will be sand/brown-colored to match my scarf, with black trim and a black UNSC logo printed on it. It adds a bit of character and functionality, almost like a warrior’s cloak, and covers my butt

I purchased the helmet files from Galactic Armory and printed them on my Kobra Max. I did some custom work on the vent details, as I plan to integrate LED headlights from RC modeling kits. In general, the helmet will be fully kitted out with electronics:

• Improved hearing (using a tutorial I found here)
• Better voice projection using a Bluetooth mic and an Anker speaker
• LEDs
• A complete ventilation system with 3 fans

The rest of the armor is being built from 10mm UHD EVA foam, 10mm HD, 5mm, and 2mm HD foam.

Progress so far:​

• Boots: Done (just need to add elastic for better form)
  (Please ignore the mess in my shed workshop)
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• Shin armor: Finished today! Though the pictures are still from yesterday – more coming later this week.
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• Hand plates and knee armor are also completed and all parts are already sealed with Kwik Seal and ready for Plasti Dip.

Next steps:​

I’ll be working on the thigh armor next, moving from the limbs inward. The final piece will be the chest armor, including the UA Relic Plate attachment (as seen in the render above). I found a 3D model for it that I was able to adjust in Armorsmith.


Speaking of Armorsmith – what a cool piece of software! It's a shame I only discovered it recently. Until now, I’ve been scaling armor parts in a much more complicated way. That said, my method actually worked better for the helmet, since Windows 3D Builder allows an x-ray view that helps check the fit precisely.


Well, this post has gotten long enough that I feel like I should leave a potato here... but I’ll spare you.


I’ll keep you all updated on my progress!
So far, I’ve spent around:

• 6 hours on scaling
• 20 hours on research
• 40–50 hours on building

With excited and friendly greetings,
Bargo~

 

[Bargo]

Hey everyone,


Today my gloves and the Nerf MA40 finally arrived, so I took the opportunity to snap a few pictures of my current progress:

Unfortunately, I still need to work on the knee plates a bit – I’m currently waiting for a new Dremel since mine finally gave up on me.


If anyone’s interested in getting the same gloves, here’s a link to them on Amazon (Germany):
Gloves - Amazon(Germany)


Also, my desert shemagh came in today as well – I’ll be using it as the scarf for the build.

(Picture from Amazon)

More updates soon!
Bargo~

 

[SpartanEC40]

It's amazing what you do!!

 

[N8TEBB]

Instead of going the usual 3D printing route, I really wanted to build the entire suit (except the helmet) out of EVA foam, making it as comfortable and flexible as possible. This is my first EVA armor build, and so far, it's been going surprisingly well!

Woohoo! Another EVA build! Trust me, you'll love wearing EVA armour.

Your foam work is exceptionally clean! ESPECIALLY for a first foam build. I'm excited to see what this looks like when it's all finished. Your plan for your armour sounds awesome and those renders look so cool. Keep up the great work.

 

[Wraith0912]

I saw N8TEBB's comment about the foam work and had to do a double take at those pictures because I could've sworn those pieces were printed at first glance. Seriously, you're doing a great job with the foam parts so far, you should be very proud of the progress you've made. I'm looking forward to seeing how everything comes together, especially the personalized pieces like the kama. Good luck going forward!

 

[Bargo]

Thanks for the compliment!
I haven’t been idle these past few weeks and I finally have some progress to show:

I’ve now completed all armor parts except the chest.
The helmet has already been reinforced with fiberglass on the inside, though it still needs an external sanding pass and the visor made and installed.

I also received the LEDs I’ll be using for the vent slots in the helmet – they’re actually RC model headlights, so they should really make an impact!

After taking these pictures, I added even more details to the armor parts and smoothed stuff out with kwickseal – like on the biceps, Shoulder and gauntlets. Those pics will be included with the chest update.


Speaking of the chest piece – I’ve already started on it, but I have to admit: it’s a bit more complicated than the rest. Sometimes my brain just needs a little break figuring out which angles go where.


That’s it for now – see you in the next update!
~Bargo

 

[Bargo]

Time for another update!
I’m currently waiting on my next Plasti Dip delivery – turns out six cans weren’t enough.


Several parts have already received two full coats, with the knee and hand plates getting the full three layers for full coverage.
Unfortunately, I didn’t have enough left to fully cover the thighs and chest armor.


Here are some photos showing the current state of things:

Here are some pictures of the chest plate:

And the helmet got a second coat of Filler this time its the Greenstuff Flexible Filler:

Build Update & Cost Overview – by Bargo​

Some info about the parts:


I’ve attached the shoulder pieces directly to the biceps, hoping it makes movement feel more in-game accurate.
Unfortunately, this means some bicep detailing is now hidden – but hey, you can’t have it all.


The belt pouches still need a closure system – I’m thinking about magnets or Velcro, but haven’t fully decided yet.


As for the chest plate, I had to improvise in a few areas, but overall I’m pretty happy with how it turned out!

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Budget Breakdown​

Purchases so far:

Item	Qty / Size	Price
EVA Foam (High Density, 10mm)	4m² (0.5m² left)	€89
EVA Foam (Ultra High Density, 10mm)	2m² (0.5m² left)	€59
EVA Foam (High Density, 5mm)	2m² (1m² left)	€34
EVA Foam (High Density, 2mm)	2m² (1.5m² left)	€18
Contact Glue	1L (150ml left)	€22
Kwik Seal	1 tube (empty)	€14
Glue Bottle	1	€3
Green Stuff Flexible Filler	250ml (150ml left)	€13
Plasti Dip Violet (on sale)	2 cans	€14
Plasti Dip Black	4 cans	€52
Rotary Tool with Flex Shaft	1	€34
iDye Poly Yellow	1 pack	€13
PETG Sheet	0.6m²	€16
USB Helmet Fans	4 (2 spare)	€9
Buckles + Nylon Belt Set	1 set	€10
Nerf Blaster MA40	1	€79
Gloves	1 pair	€20
Shemagh (Scarf)	1	€12
Helmet LEDs (RC Model)	2	€6
Sandpaper Bundle	–	€14
Tactical Pants	1	€30
Combat Shirt	1	€31
160g Template Paper	1 pack	€4
Replacement Blades	50 pcs	€13
Filament for Helmet	–	€45
3D Helmet File (Galactic Armory)	–	€24

Total spent so far: €589

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Watch Time During Build​

Because we all know a good build needs good background entertainment:

Show / Season	Hours
Reacher (S1–S3, 8 eps each @ ~48min)	19.2 hrs
Log Horizon (S1 & S2, 25 eps @ 25min each)	20.8 hrs
Solo Leveling (S2, 13 eps @ 24min)	5.2 hrs
Fullmetal Alchemist (2003, 51 eps @ 24min)	20.4 hrs
Hunter x Hunter (S1+S2, 136 eps @ 23min)	52.2 hrs
Übel Blatt (12 eps @ 24min)	4.8 hrs
I’ve Somehow Gotten Stronger… (12 eps @ 24min)	4.8 hrs
From Common Job Class to Hero (12 eps @ 24min)	4.8 hrs
I’ve Been Killing Slimes… (15 eps @ 24min)	6.0 hrs
Last One Laughing (S6, 6 eps @ 28min)	2.8 hrs

Total Watch Time: ~141.2 hours

Working Time​

Including planning, waiting times (e.g., for materials or drying), and periods without any show running in the background, I’m at roughly:


️ About 170 hours of pure working time


This covers everything — from research, template creation, cutting, gluing, sanding, painting, test fitting, to final assembly.

So far so good!

~ Bargo

 

[valyriel]

Your foam work is very clean! Looking great so far

 

[Bargo]

Hey folks!
It’s been a while since my last update — life got in the way, and as much as I’d love to say the build is finished, other things took priority.
But that doesn’t mean I’ve been completely inactive.

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Main Update: The Helmet​

The helmet is now fully finished, except for the missing Bluetooth mic. Here are a few pics:

I managed to cram in everything I hoped for:

• Thanks to an amazing hearing system tutorial here on the forum, I decided to use Zohan ear protection headphones with audio enhancement.
• I integrated them in a way that the helmet fits snugly and I can hear clearly. The microphones are positioned at the temples, where I drilled small holes into the helmet detail — works great!
• I also added an external orange LED to indicate whether the mic system is active or muted.
• Two 5V fans are installed for cooling and potential anti-fogging.
• And finally, I added RC model headlights to complete the whole look.

All electronics are wired in parallel to a single USB plug, so I only need one power bank inside the helmet. Now I just need to run a few runtime tests to see how long it’ll last.

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Visor Trials and Success​

Initially, I tried vacuum forming a visor using PETG and iDye Poly — while dyeing went great, I overheated the plastic during forming, resulting in internal bubbles.
Still, I gave it a shot and sprayed it with MTN 94 Silver and cheap chrome spray… but visibility was awful. I could barely see through it.


So, new plan:
I printed the visor from Galactic Armory’s files using clear resin (same scale as the helmet – 105%). Since my printer is small, I split the visor into four parts, then glued them together with resin after curing.


After tons of wet sanding (grits: 240 to 3000) and polishing paste, the visor was crystal clear — even for resin!


As I no longer trusted my spray paints, I searched for alternatives and found a chrome mirror paint used for decorative purposes Amazon link. The paint is super thin and airbrush-compatible.
So I got myself a budget airbrush & compressor set Amazon link — for ~€75 it’s honestly fantastic and not too loud.


I applied the chrome paint in 2–3 light layers on the outside of the 5 mm visor, then buffed it with a microfiber cloth…
And wow. You can’t see in, but you can see yourself in the reflection — while still being able to see out from the inside!
There's a slight fisheye effect, but it’s manageable.


After that, I permanently installed all electronics and padding inside the helmet. The power bank is swappable, held in place with a Velcro strap.

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️ Armor Status​

All parts have been painted, and most are just waiting for final weathering.
Once that’s done, it’s time for strapping and soft parts tailoring.
The pressure is on, since my deadline is Gamescom Cologne — I plan to wear the full kit on Thursday and Friday!

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Budget & Time Update​

Additional Purchases​

Item	Qty	Price
Mini Powerbank (5000 mAh)	1	€18.99
Helmet Padding	1	€9.99
Zohan Ear Protection with Audio Enhancement	1	€43.99
Sole Rubber Plates	2	€18.99
Wood Circle Cutter	1	€12.99
Metal Clips	25 pcs	€5.99
Headlight Polishing Set	1	€21.95
Airbrush with Compressor	1	€75.80
Chrome Paint	1	€13.95
Anycubic Ultra Tough Resin (Crystal Clear, 0.5kg)	1	€16.00
Hot Glue Gun + 10 Sticks	1	€6.00

Updated Total Spent​

• Previous Total: €589.00
• New Additions: €243.64
  → Grand Total: €832.64

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Time Spent​

• +30 hours since last update
  → Approx. 200 hours total work time (excluding planning, waiting & testing)

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Let me know what you think — feedback always welcome!
And if you’ve for strapping tricks for mobility and durability… I’m all ears.
Next stop: full kit test fit


~ Bargo

 

[Skidmorpheus]

Excellent work! Also the running cost breakdown is equally as impressive. I should be more organized. lol

 

[Bargo]

[Full Armor Test Run – After 18 Years, My Halo Dream Is Real!]


After months of building (and years of dreaming), I finally suited up in my complete Halo armor for the very first time!
From scorching sun to uneven terrain, I put the kit through a full 7-hour, 5.5 km field test – and I’m thrilled to share the results, the tweaks I’ll be making before Gamescom, and a few first-look pictures of the full suit in action.


Hey everyone,


I’m beyond happy right now – yesterday I finally completed my armor harness system and was able to wear my full kit for the very first time!
Up until now, I’d only been able to wear parts of the armor since I never had a “squire” around with the time and patience to help me suit up fully.


Long story short – I took the opportunity today to do a full test run at a cosplay meet-up I organize a few times a year with friends in Oldenburg (Germany, Lower Saxony).


Test conditions:

• Weather: 28 °C, sunny, almost no shade, light breeze
• Terrain: gravel, cobblestones, mowed grass, tall grass, and standard tiled floors
• Distance: 5.5 km
• Duration: 7 hours

Damage during test:

• The “tongues” / top covers on my boots came loose – fixed on the spot with superglue, no problem.
• One switch inside the helmet came loose – will need to re-glue it.
• Apart from that, nothing broke!

Things to improve:

• Reposition the speaker so it doesn’t poke out under the chest plate when stretching.
• Rotate the helmet microphone and increase the distance between the hearing enhancement mics and the voice amplifier to avoid feedback during trooping.
• Add an extra front connection between the belt and harness system to keep it at the right height.
• Possibly add another cross strap to balance the left side load (from the pouch) with the right side to avoid tilting.
• Add a high-absorbency cotton undershirt beneath the combat shirt to delay sweat salt marks – towards the evening, I noticed light stains on the harness straps from dried sweat.

Powerbank test results:
Fans + hearing enhancement system were running constantly for 5–6 hours. At the end of the event, I still had 3 out of 4 bars left – so a full con day will be no problem with the 5000 mAh battery.


Photos:
The shots you’ll see were taken right after suiting up at the car (without any adjustments or “pulling” things into place). No proper photoshoot this time, but I might get one next week if my wife and I decide to go to a local con spontaneously.


I’ve also decided against using the shemagh – looks better without it and improves airflow. Originally, I had planned to add the UA Relic Plate as a chest attachment (I even made Pepakura templates), but in the end I preferred the standard chest plate – it shows off more detail in real life.


Now it’s just down to a few final touches: decals (Spartan-II logo on the chest, UNSC logo on the brown kama), and maybe some small detail additions here and there. The changes are quick to do – so Gamescom, here I come!


Final thoughts:
I’m incredibly happy. Yesterday it hit me that I’ve wanted a Halo suit for 18 years – and now it’s finally real!
This build contains 10 years of cosplay experience, around 250 hours of work, and about €800 in total costs (which is less than I expected when I first started).

~ Bargo

 

[Bargo]

Gamescom Update!


Hey Spartans,
what an incredible weekend it has been! I had the chance to meet so many amazing people, got photographed by literally hundreds of visitors (including by Gamescom staff themselves!), ended up on live TV with “Welt”, appeared in some other news outlets, and even got posted on Instagram – so yeah, I’d say it was a full-on success!


I’ll drop some photos below to give you all a few impressions from the event.


As for the armor itself: it held up really well! Only two small things need to be re-glued, but otherwise everything stayed in place perfectly. The only real downside I noticed was the helmet – it’s quite heavy, and after the second day I was completely done. My neck and back definitely let me know they weren’t happy about it.


I’ll have to figure out a solution for that:

• maybe wearing a back support brace under the undersuit to relieve the lower back,
• training my neck and shoulder muscles a bit more at the gym,
• or even building some kind of hidden rest/brace inside the suit where the helmet can sit when needed.

Or… maybe I should just take more breaks without the helmet instead of wearing it at “half-mast” That might help too!

This funny looking guy on the left is a culture good from germany, we say: "Nichts beschreibt Deutschland besser als ein depressives Kastenbrot im Kinder Fernsehen" translate: "nothing describes Germany better then a depressed Bread in the Offical Kids TV"

my personal highlight! meeting all of you <3

All in all though, I couldn’t be happier. The experience was unforgettable and this build truly paid off at Gamescom.

When you forget that there are People around and you just get in vibe (German Intro Music to Sailormoon)

 

[N8TEBB]

So glad you had a wonderful time at the con! Your suit looks AWESOME!

As for the heavy helmet issues, it doesn't hurt to do all three. Taking extra breaks, training those muscles, and even making a lighter helmet will all help you ache less after those long con days.