Thorssoli's HALO 3 Marine(s)

thorssoli · Mar 3, 2011

A while back, I was contacted by another maker asking if I'd be willing to trade one of my Sniper Rifles for a few sets of his vac-formed marine armor. I agreed, but it doesn't look like his armor comes with helmets. Undaunted, I surfed my way over to the halo costuming wiki, downloaded the HD Marine pep file, and a few short hours and half a bottle of wine later I had the pep build knocked out.

The next day, I went ahead and coated the outside of the helmet with a thin layer of polyester resin (aka hardware store fiberglass resin):

Once the polyester resin had cured on the outside, sealing up all of the small holes where things might leak out, I went ahead and reinforced the inside with some black casting resin:

I added the black pigment to make it easier to see where I hadn't managed to slush the resin on the inside of the helmet.

(NOTE: you could just as easily go ahead and lay fiberglass mat and resin on the inside instead of the casting resin)

Now that I've built up enough thickness for the helmet to have some strength, it's time to start the bondo work.

Since I'll end up with more than one set of armor, I'm planning on making a mold and cranking out a handful of castings of this helmet.

Stay tuned...

Jico · Mar 3, 2011

Awesome! im looking forward to see this become another thorssoli masterpiece

JUSTINIAN 117 · Mar 3, 2011

I've been looking for an amazing thread for this. I can't wait to see how it comes out.

Tactonyx · Mar 3, 2011

I'm gonna be watchin this

Brandon McClain · Mar 3, 2011

As always, I love seeing you taking on a new project! Your work is never anything short of flawless!

Cjsuner · Mar 3, 2011

sweet! do you have any plans to cast and sell the helmets? (instead of just catin the few)

TyrDropProps · Mar 3, 2011

Did the resin make it to the inside of the ear pucks?
If I remember correctly, they're completely separate pieces.
And I must say that I'm surprised you didn't just have Lopez whittle them out for you to add later.
Can't wait to see how this turns out.

Road Kill · Mar 3, 2011

very nice helmet man, looking great and keep up the good work, can't wait to see more

thorssoli · Mar 3, 2011

Cjsuner said:
sweet! do you have any plans to cast and sell the helmets? (instead of just catin the few)

I'll probably sell a few, yes. If you don't see me post a classified thread, you can always PM me if you're interested in one of my pieces or, better yet, email me at sthorsson99@yahoo.com.

Wtfmfkr said:
Did the resin make it to the inside of the ear pucks?
If I remember correctly, they're completely separate pieces.
And I must say that I'm surprised you didn't just have Lopez whittle them out for you to add later.
Can't wait to see how this turns out.

No resin in the ear pucks yet. They are separate pieces, yes. I'll be cutting holes on the inside and filling them from the inside. Once the ears are solid, I'll be carving in the notches with the Dremel tool.

Lopez has been down for a couple of weeks while I'm waiting on a couple of repair parts. He's a wonderful machine when things are going smoothly, but when he fails he fails spectacularly. It's too bad too. He could've been working on the whole helmet while I was making progress on my ODST builds or my shotgun or any of a dozen other things I've been neglecting lately.

JUSTINIAN 117 said:
I've been looking for an amazing thread for this. I can't wait to see how it comes out.

Then I hope it turns out amazing...

As always, thank you all for the kind words. All of my projects are fueled by praise. That, and/or alcohol apparently.

TaKaGaRi · Mar 4, 2011

Very cool once again Shawn.
I'm wanting to get one of those too. so keep it up

Shawn

thorssoli · Mar 8, 2011

Minor update.

Fairing has begun:

Stay tuned as I knock out this vital stage of the project.

sildeo · Mar 8, 2011

looks good cant wait to see more

thorssoli · Mar 9, 2011

sildeo said:
looks good cant wait to see more

Here's more:

thorssoli · Mar 12, 2011

I'm going to call this one 98% done.

There's still a couple little details to add to the ear pucks and I have to smooth out the underside of the bill and do a tiny bit of filling, but 98% seems right.

Did I miss anything?

Gallard · Mar 12, 2011

I dont think so.. I compared it with a sculpt I saw and there seems to be every single detail you have. The only difference is some of your raised areas were dpressed compared to his but knowing how hard it is to find detail fro the game I would have to say paint her up!

thorssoli · Mar 12, 2011

Gallard said:
I dont think so.. I compared it with a sculpt I saw and there seems to be every single detail you have. The only difference is some of your raised areas were dpressed compared to his but knowing how hard it is to find detail fro the game I would have to say paint her up!

I still have to do a very little bit of feathering-in some bondo and add the little rectangles on the outsides of the ears. I'm also thinking I'll add a bit more texture to the parts that will end up painted black. Then I'll mold it and cast a few copies before I bother with a finished paintjob.

BLACKULA727 · Mar 12, 2011

Does everything you touch turn to gold? Anyways, great eye for detail. As always it looks really good!

thorssoli · Mar 12, 2011

BLACKULA727 said:
Does everything you touch turn to gold?

Nope. In fact, much of it turns into a pile of pink Bondo dust on the workbench.

Enough poking around online for now. Time to go get to tinkering.

thorssoli · Mar 13, 2011

Just about done:

I've added the rectangles on the ears, fixed the raised area under the brim, and done a bunch of sanding. I need to straighten out the leading edge of the brim and add texture to the areas that'll be painted black, then it's time for molding.

If you click on the picture above, it'll take you to my flickr photostream for more pics from more angles.

Again, did I miss anything?

thorssoli · Mar 14, 2011

Today I taped off all of the areas that will be painted black on the finished pieces and sprayed them with a thick coat of Duplicolor Truck Bed Coating:

I'm not worried about the color at this point. The black is to get the texture I wanted:

At some point in the coming week I'll be making the mold. In the meantime, I'm experimenting with potential paintjobs in photoshop:

I've got a few different ideas:

I'm still willing to entertain suggestions...

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