Cosplay Gen: How did you make the Master Chief suit?
Zam: The process is actually simple. The base layers are made from a thick 250gsm matte card. Here, the details and main structure come to life. After that, all the finished paper structure is covered with fiberglass resin to make it rigid. Matte Card absorbs it and becomes rigid from inside out. Fiberglass mat was used in the inside to avoid the details on the outside getting covered. The fiberglass just makes the paper structure more rigid so it can withstand some sort of damage when wearing it.
Next step would be poly putty. Poly putty is the same stuff most paint shops use to make the surface of the car smoother. Usually they use the brand Bondo outside Malaysia. This step is to make sure the outside surface is smooth and aligned with the rest… next would be prime and paint … Wirings are really simple. The resistor value used depends on the amount of the LED used, battery voltage input, and how it was wired. Most of the stuff on how to make it I learnt from 405th.com. It’s the biggest Halo related community on building your own armor.
Malaysians can go to 901st.com. I was its founder, and I would love to help anyone who wants to make their own stuff. The reason for which I made that community forum is because most of the stuff or material used by the 405th isn’t really easily available here in Malaysia. So we would need to find a replacement for them. Since I’ve done it, I can help guide them on making their own stuff. Pictures of the process are also available on my blog @ zamsjournal.com. Just use the tag HALO, Cosplay, DIY.
Master Chief suit Cosplay
Sherman Anion (TIME Studios)