I'm working on the visor tutorial now. Since it is basically ZakuAce's workflow with some additions I'm wondering if I should just ask him if I can post on his thread.
I think I came up with a good way to mount the shoulders. I did a mock up of a shoulder base in maya and unfolded it.
This was my first time working with foam. It's pretty nice. Its definitely quick but I don't think the foam itself is nice looking enough to go straight to painting. Sure it looks good in pics but in person not so much. That's just my opinion though.
Here are the parts with my decked out shoulders. There parts just need the weathering to be finished. Gotta wait for the storm of the century to finish though...
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I'm going to go ahead and give you guys the cliff-notes on how to do this visor, just to keep it simple.
The right plastic! You need a plastic that's sturdy enough to hold it's shape and thin enough to fold without breaking. This is the stuff. You want a 9x12 inch sheet, any smaller and you won't be able to fit the template on it all the way. You'll also want a sheet that has a thickness around .03 inches.
Mirror tint. I use the tint for buildings because it has a higher light transmission and looks cooler. Auto tint works too, but it may not be as reflective as you like. Everyone talks about how hard this stuff is to work with, but you HAVE to apply it on the plastic sheet BEFORE you cut out and make your visor. Some tints do have colors but in my opinion they don't match anything halo related, and they also have a low light transmission so... I use this. It's 50% LT and the standard silver. It's nice to have a basic silver so that you can make any color visor you want
X-Metals paint. The blue color works fine for standard ODST's. Keep the coats very thin, and very light. This will affect your clarity if you're not careful, but you can see through it. For Halo 3: ODST use a VERY light coat, you'll want a very diffused blue. The yellow could sort of kinda look gold, but I'm sure there are other paints that work better.
Get a visor template. I have one available on the front page. Use whatever suites you
Basic stuff - Apply the tint on your sheet. You'll also need to get the window tint application solution! This is important, it does NOT come with the tint! Trace and cut your visor, assemble, and paint. You could also paint the plastic before you cut the parts out. I would have done this but it was night time and cold outside.