HALO 2 Master Chief Armor: Helmet

What a game! What a cool suit of armor! I wanted to build this suit but the real test is building the helmet. I figure if I can pull that off the rest of the suit should be no problem....right??....right?



I've seen other people make their Halo helmets by sculpting it out of clay, making molds, pouring resin, etc. Me only know styrene so that how me make it!

I started with a basic batting helmet. I found one that was a bit small on my enormous melon so that when the final helmet is complete I wouldn't look like a bobble-head. I tore out all the padding so I could add it later once I saw how the final helmet fit.



I cut off the visor (brim?) and a bit off the side to get the basic shape.


I screwed on a strip of steel for the jaw portion of the helmet.

To work out the basic shapes and how they fit on the helmet, I got a pack of poster board and worked out my templates ( I only did half).

Using sheet styrene I assembled the lower jaw. I made a track just below the top for the steel strip to fit into.


The visor and cap sections were built much the same way...kind of a hull structure (.080) that I would skin with thinner plastic (.040).

Unfortunately, I am not that precise with my cutting so I rely heavily on putty to cover my mistakes!

The back under construction....

and skinned.

I used a 2-part epoxy foam to fill all the structural parts. Now the helmet is solid and heavy! Bring on the Covenant bastards!


Here it is assembled with a thin support rail for the visor. I also inserted some rubber hose for the respirator. I plan to add cooling fans behind these.

Now..how to cut a face plate to fit. How about little strips of poster board taped together?


Flatten it out and trace! A perfect match.
  ¶ 11:26 PM