Here is my most recent suit. Not gonna lie I could have spent more time and it would have looked better but I use it in high stress activities for costumes. Sorry about the rotation issue. Haven't quite figured it out yet.
Thank you! I do not have a full tutorial since I was following other tutorials already lol. It was 100% pepakura all from the high def files on the wiki. I really lucked out on the measurements and only ended up making 1 extra piece. There are dozens of amazing tutorials you can follow on here. http://imgur.com/a/2PpEK/all There are a few more pictures for reference. Feel free to PM me if you have any specific questions!
Now that I have finally finished, here is my contribution...
Post Escalation Master Chief with custom, full body Exo-suit.
Helmet was an Impact cast, visor by Hector Alfaro.
Wearer is Jonathan Groves from "World's Tallest Spartans".
Photo shoot location: Ft. Casey State Park, Washington State
Photo Edits made by Epic Edits (no editing to the suit was made)
Over 3000 build time hours and thousands of dollars invested. Primary components are made from Balsa, Rondo casts, EVA Foam, and Custom made Latex Hex Pattern.