HALO 2 Master Chief Armor: Chest Armor
Like the helmet, I first constructed posterboard templates for each part of this complex suit of armor. Being symmetrical, I only drew out half of the detail.
Using a heat gun, I carefully bent the plastic into shape. Larger pieces are much harder to form using the gun as you can only heat a small area at a time.
Once it was folded over, I glued the side panels to lock it into shape.
The pec plates were built out with supporting ribs of thicker plastic and filled with expanding foam for support.
The "shoulder boxes were built much the same way...
...as was the "vent box" at the base of the neck. I built a separate vented panel to fit into this later.
The "back boxes" were built around the shoulders.
The unit was fitting a bit funny so I decided to take a page from the Stormtrooper Armor guys and separated the front from the back, hinging it where the shoulder boxes meet the back boxes. This also allows it to fit over my head easier!
It was also easier to work on these as two different pieces. I added boxes below the back boxes.
I trimmed the bottom edge to the proper distance and added a second level of detail at the ribs and sernum. This also made it much stronger.
The upper stomach plate will be hinged after painting.
Painted all the parts with a few coats of primer and 2 coats of glossy green paint. This will eventually be weathered for a battle-scarred finish.
I epoxied web straps with industrial strength velcro at the joints.
The final armor! (There's a few more details I will add if I have time)