Foam MJOLNIR Mark VI - Halo 3 Foam Build Thread

[Mirrorbright]

Vacuforming is such a satisfying activity for me.

During experimentation, I found that .030 PETG worked best for the outcome I wanted.

 

[Mirrorbright]

Next step, take my good pulls and dye them deep orange using iDye Poly. Then spray the inside of the visor with a few coats of Alclad II Chrome.

 

[Mirrorbright]

I used superglue to affix the visor to the rest of the helmet, but I didn't like how it interacted with the PETG visor. If anyone knows of a better glue or way to put in a visor, please let me know!

Here is a glamor shot when it was all complete. I also added LEDs and padding, but I'll go into that a little later, Additionally I vacuformed some white styrene as the light covers.

 

[Mirrorbright]

I used superglue to affix the visor to the rest of the helmet, but I didn't like how it interacted with the PETG visor. If anyone knows of a better glue or way to put in a visor, please let me know!

Here is a glamor shot when it was all complete. I also added LEDs and padding, but I'll go into that a little later. Additionally I vacuformed some white styrene as the light covers.

View attachment 309427

 

[S225]

Very impressive! I've been considering a vacuum formed visor after a few attempts at a resin one. You make it look easy.

 

[Mirrorbright]

Very impressive! I've been considering a vacuum formed visor after a few attempts at a resin one. You make it look easy.

Thanks! I wish it was that easy. I probably had about 10 attempts before I got a few pulls that I liked. Thankfully I found a place that sell huge rolls of PETG!

 

[marinesniper]

Thanks! I wish it was that easy. I probably had about 10 attempts before I got a few pulls that I liked. Thankfully I found a place that sell huge rolls of PETG!

what place did you find that sold rolls of petg i have ben trying to get plastic for my visors but everyone is back ordered

 

[TurboCharizard]

I used superglue to affix the visor to the rest of the helmet, but I didn't like how it interacted with the PETG visor. If anyone knows of a better glue or way to put in a visor, please let me know!

Here is a glamor shot when it was all complete. I also added LEDs and padding, but I'll go into that a little later, Additionally I vacuformed some white styrene as the light covers.

View attachment 309427

CA really likes to craze and create a mist on thin clear plastics so that's unfortunately just part of life when attaching visors that way. Hot glue or a two sided tape are options that will help limit the smoking of the visor when you try your next one.

 

[Mirrorbright]

what place did you find that sold rolls of petg i have ben trying to get plastic for my visors but everyone is back ordered

I went to my local Piedmont Plastics, but this was a few month ago. Thankfully they had one last roll, but they also have a webstore.

Piedmont Plastics

 

[Mirrorbright]

CA really likes to craze and create a mist on thin clear plastics so that's unfortunately just part of life when attaching visors that way. Hot glue or a two sided tape are options that will help limit the smoking of the visor when you try your next one.

I also tried hot glue one but I didn't like the hold I got.

I have also seen this product being used, I wonder if anyone here has had good results with it.
https://www.amazon.com/J-B-Weld-8267-S-SteelStik-Reinforced/dp/B000786GLM

 

[TurboCharizard]

I also tried hot glue one but I didn't like the hold I got.

I have also seen this product being used, I wonder if anyone here has had good results with it.
https://www.amazon.com/J-B-Weld-8267-S-SteelStik-Reinforced/dp/B000786GLM

You definitely have to go slow with it and hold everything in place while the glue sets up. Work in small sections and have compressed air or another way of speeding up the set will help.

 

[MrJamin]

Wow - this is very very impressive! The helmet and visor look terrific. I never would have thought of doing a gold base, but wow it looks great.

I had some of the same issues with CA glue and the haze/mist. I was able to clean some of it off with a clean cloth and some water. (didn't want to use any chemicals) I've also seen different brands of CA glue do this more than others. (BSI has done it less than others for me)

 

[Mirrorbright]

I initially wasn't going to have a bodysuit, but decided it would be best if I made one. Ordered this pattern, although I think it's technically discontinued.

Fabrics used:
Arms: Are You A Bot?
Torso: Are You A Bot?
Legs: Are You A Bot?

Edit: I'm not a bot

 

[Mirrorbright]

My wife did the sewing! The arms were more bulky than I thought they would be, which is perfect. Helped fill out the spaces between the armor parts. Also made the collar twice as tall so it hides more of my neck.

 

[Mirrorbright]

I have started researching and going to do some experiments on adding the patterns to the midriff. Planning on making some molds, and casting with latex. I'll update this post with the results in the future.

 

[Mirrorbright]

Now for what I'm super super proud of: The MA5C Assault rifle. This was my first time patterning something from scratch. I usually use exiting templates or patterns.

Used Inkscape to trace over a photo of the rifle, printed out the blueprint (several times), and started assembling a prototype to make sure I was on the right track and had the right dimensions.

 

[Mirrorbright]

The finished rifle is a mixture of 10mm, 6mm, and 2mm foam. The key was to get the basic shape, then slowly build up layers. Lots of experimentation to confirm I was on the right track. Also some of the pieces needed to be cut at a 45 degree angles, and/or shaped with a Dremel.

Here is the result:

 

[Mirrorbright]

I had heard good things about using Alclad II lacquers to paint metallic on foam, so I decided to try it. It didn't disappoint. I didn't do a great job with the shading here, I think it has to do with using lacquers and not actual paint. More for me to learn eventually.

Used Polished Aluminium and Steel. Works best to paint over a base of glossy black, and again it's more for me to learn. The glossy black I used wasn't great on the sealed foam. Next time I'm going to try to use Alclad's primer they have.

 

[Mirrorbright]

More future plans: I'm going to make a video showing details of the steps to make the rifle, and maybe even release the plans I have. I need to clean them up a little first.

Update! Video is done:

If you want the blueprints, DM here (Not on YouTube). Anyone messaging me here on the forums I'll be happy to send it to.

Update 2: Another video showing the paint job:

 

[Mirrorbright]

Instead of writing about the strapping, I'll post this video of me talking about the different ways the armor is strapped to my body. Strapping is always something that I initially overlook, so I was glad to be able to take some time this time to go through a few iterations on how it might work.