Commander Sarah Palmer - Scout variant of the MJOLNIR GEN2

GeekGuardianDee · Jun 17, 2014

This thread will follow the creation of a Scout variant of the MJOLNIR GEN2 armor, as worn by the character Commander Sarah Palmer a SPARTAN commander in HALO 4. The photo, below, shows the armor and some details.

Most of the research for this project has been conducted through repeated searches of the 405[SUP]th[/SUP] Infantry Division forum, with some Google-fu of progress articles and material suppliers. Details of the research conducted, and the sources used, will be provided in additional posts, below.
Please Be Patient As This Thread Populates, reserved areas are provided to help structure the information for others.

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GeekGuardianDee · Jun 17, 2014

Introduction

As the Halo: Master Chief Collection is set to release for XBOX one this November, and I have promised to purchase it for my husband the day it comes out, there has been a lot of looking into the HALO works in the past weeks. As we have been looking into various group cosplay options for us as a couple HALO seemed an obvious choice. While I will also be creating another couple of cosplays from comic book inspiration, HALO will be the cosplay that we will do together. I have chosen to create the Scout variant of the MJOLNIR GEN2 armor worn by Commander Sarah Palmer in HALO 4, mainly because it is the only female character detailed in the HALO 4 wikis.

HALO: Master Chief Collection Trailer

While there are different approaches to how best to create this armor, the methods attempted will be chosen as each piece progresses based on the work completed previously. The pieces that will be attempted include:

Inner skinsuit
Cooling system
Bodysuit
Scout chest
Scout shoulders
Scout helmet, with pioneer visor
Inner-plated wrists
Outer-plated legs
Electronic LED Circuits
M6H magnum sidearms

This thread will, hopefully, become a beneficial resource for myself, the 405th division, and other armor makers. This write-up will provide a space for;

Communication with other, more experienced, 405th members,
Complication of resources and references for future use,
Chronical of methods, supplies, costs, and time required for various components,
Discussion of methods, results, and mistakes along the way,
Photos and/or videos of completed works, progress updates, and how-tos.

While I do have previous experience with sewing and basic handicrafts for costuming, and have spent many hours researching traditional armor making techniques for recreation purposes; my fabrication skills are based on model making and are pretty much at a rank n00b level. My husband, a machinist, will most likely be helping me with much of the manual fabrication tasks, but my OCD planning and detailing will be the spark that brings this project to the next level. While I might feel bad about making him do most of the hard work, I think the final tally may be about equal in the end.

Most of the methods and techniques used for this project will be taken from other's work and tutorials online. One important item that will be tested in this build is the creation and implementation of an built-in cooling system to provide comfort to my husband and I while we wear these suits. This system will be created like a CPU water cooling system with contacts at the body's pressure points. The methods used for this system and its results will be discussed in detail throughout this thread.

GeekGuardianDee · Jun 17, 2014

Research Materials

While many articles and posts were read in order to begin the planning process for this project some will have more influence on the actual work than others. Any techniques or write-ups that prove particularly relevant are summarized here.

General Information:
All-In-One New Member Introduction Guide V1.3

This really is the first steps, and the basics for every topic you will need to familiarize yourself with to begin a HALO suit. While this does not provide a step-by-step work through there are links to more detailed articles relevant to each phase of the suit construction. Link: All-In-One-New-Member-Introduction-Guide

Build Threads:
Carpathia's Mk VI Armor: Master Chief Going into Cryostasis!

This extremely comprehensive build thread demonstrates; adding detail to fibreglass armor, creating fibreglass and foam boots, adding foam padding to the armour pieces, and adding battery operated LEDs into the armour. Definitely do not miss reading through this build thread. Link: Carpathia's Mk VI Armor: Master Chief Going into Cryostasis!

ChefBZD's foam Master Chief WIP

This build thread was recommended to me by @<i><a href="http://www.405th.com/member.php?u=28676" target="_blank">WandererTJ</a></i> as it contains some very good ideas for the creation of the H4 exo-suit. The build itself is foam, which is not what I am using for the armor portions of my build, except for the exo-suit construction. If you are looking for the relevant exo-suit posts follow the link provided here and navigate to page 7. Link: ChefBZD's foam Master Chief WIP or go directly to Page 7

HALO 4 SCOUT full build.....stony props style by Jim

Great example of the details of the Halo 4 scout. While this work was done with foam, a medium I will not be using for this Sarah Palmer build, it provides a lot of inspiration for the quality level I will need to bring to this build. Link: HALO 4 SCOUT full build.....stony props style by Jim

LongShot-X's Mark VI HD MJOLNIR Armor - WIP

I met Long-Shot-X at a con last year, and while planning out the Sarah Palmer build I thought I would look him up. Found his website and his build thread posted here on the 405th forum. There is a lot of helpful information about the techniques that were used to create this build, including tips on how Kevin made particular tasks easier for him (specifically his pepakura tips). Another great thing about this build is that is was completed by a 'Noob', so it IS possible to make a great suit right out of the gate. I recommend checking out his forum thread here and his website. Link: LongShot-X's Mark VI HD MJOLNIR Armor - WIP and www.LongShot-X.com

My first "Halo Reach helmet and armor build"

Renraku's build thread gives a thoroughly detailed explanation of the rondo process for his helmet. It includes; adding details, providing vents and fans, and detailing and installing the helmet visor. The armour build itself is foam and there are some tutorials for foam building techniques as well. Link: My first "Halo Reach helmet and armor build"

Scaling Pepakura:
How To Scale Pepakura

This video gives a very succinct walk-through of how to measure, scale, and adjust to get the best fit for you pep pieces. CEREAL KILL3R's troubleshooting tips at the end for how to make a well-fitting piece able to be put on and taken off are very useful. Link: How To Scale Pepakura

HaloGoddess' "How To Scale" and More Tutorial *REVISED*

This thread and its information is a very good breakdown of the scaling steps. The images and diagrams in particular help focus in on the key measurements and steps that are required. This information is listed on the forum here and on HaloGoddess' website; check them both out as the information is not a direct duplicate. Link: HaloGoddess' "How To Scale" and More Tutorial and Scale Your Armor in Pepakura - HaloGoddess

Hardening:
The Basics of Fiberglass Fabric

A great video explaining the different types of fibreglass commercially available. The video details cloth versus mat, weight of fiberglass, fibre weaves, and the different fiberglass types. Will give you a good basis to answer the question, "What fiberglass should I buy?", for you own build.

Finishing:
Armor Fitting and Strapping 101

This thread provides a step-by-step guide on how to strap the armor pieces to your torso so that the weight is evenly distributed and the pieces stay in the right places. Link: Armor Strapping 101

Auxiliary Systems:
PC Liquid Cooling System: Build it Yourself

A very basic description of the materials and techniques for putting together a custom CPU water cooling system. Methods for integrating a water cooling system into this HALO build are based on this article; although greatly expanded upon and modified. Link: PC Liquid Cooling System: Build it Yourself | PCWorld

GeekGuardianDee · Jun 17, 2014

Methods

This space will provide a basic description of each of the component pieces for the project, along with links to the project updates pertaining to each piece. Photos and discussion of each completed piece will be posted in the next section.

Inner Skinsuit

Current Phase: Planning
Current Phase Progress: 10% complete
Overall Progress: 4% complete
This item is described at HALOPEDIA as being 'made of a moisture-absorbing synthetic material linked to an environmental control computer and the occupant's neural interface. It controls the suit's temperature and actively changes how the suit fits the user." While the environmental controls and the adjustable fit are beyond the scope of this recreation, it sounds like a wicking athletic outfit will do the trick here.

Spartan 4 Exo-suit

Current Phase: Planning
Current Phase Progress: 90% complete
Overall Progress: 32% complete
This is the portion of work where my sewing experience will do me well. Based on the reference pictures, included below, this suit will significantly change the dimensions used as a baseline for any external armor plating. So, this appears the be the natural starting point for my project.

Links:

Update #1

Scout Forearm and Handplates

Current Phase: Construction
Current Phase Progress: 15% complete
Overall Progress: 45% complete
Scout Forearms are generally smooth with an elbow covering piece that extends beyond the tip of the elbow. Geometry from the Halo 4 Male model does not fit the female physique that is accurate to Sarah Palmer. New 3D models based on the female model were created by Master Builder.

Pepekura schematics have been modeled specifically for this build by Master Builder and can be found at the 405th File Archive (Here's a Link).

Scout chest

Current Phase: Planning
Current Phase Progress: 10% complete
Overall Progress: 4% complete
The Scout chest piece includes a rectangular protrusion above the sternum. While I do not know what actual purpose this piece is supposed to provide to the armor, it will provide an excellent housing location for a cooling radiator with a fan in the chest piece itself. Power for the fan will be provided along the same circuit as the two LEDs in the chest, and the fan unit will also help keep the chest area and lights cool.

Pepekura schematics for the scout variant chest have yet to be located, but I am sure further searches will dig one up somewhere.

Scout shoulders

Current Phase: Planning
Current Phase Progress: 10% complete
Overall Progress: 4% complete
The Scout shoulder schematic was located in the 405th database.

Scout forearms