RobotChicken's Halo 3 Mk VI Master Chief, Ultra Detail, First Build WIP (many pics)

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Nah, resin soaks into the paper and doesn't really obscure small details - the thing I'll need to be careful about with this piece is resin "pooling" in the small crevices. To combat this, I'm planning to apply NO resin to the crevices from the outside and instead saturate those areas from the inside (after the outside is hardened) where I don't really care about pooling. I'm actually looking forward to putting bondo on these parts because until then the rounded areas are all "stair-cased" and look pretty bad. The trick here is to apply the bondo sparingly, only as needed to smooth out the surface. The 3/8"-thick "I'm decorating a cake!" approach just will not be seen in this build, sorry.

wow....This is a piece of advise.......have you tried it before?
 
wow....This is a piece of advice.......have you tried it before?

No, I've never used Pepakura prior to this project - this build is my first of this kind. But the rationale is sound based on the physical behaviors of paper and liquid resin, and my experience with hardening the first pieces.
 
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The next custom detail to be added is the grooved line around the lower portion. I expect it to be groovy. :p

Looking forward to seeing how you tackle the grooves in pep. That's usually something that's carved in post-pep. (If we're thinking of the same thing. It's hard to describe this stuff just with words.)

Inspired by your progress, I've been working on some perspective sketches for the forearms. Outlining the details I can make out from reference images, and interpreting the areas I can't.
 
Not all the lines are straight. Some are curved and would be difficult to carve, cut, or scribe into a hardened piece. (Taking power tools to bondo is not something I'm very keen to do, and scribing into resin by hand would be way harder than what I'm going to do. I also don't have faith that I could do clean lines with an engraving tool.) Bondo is brittle and chips easily when cutting into it, so in my (amateur) opinion it will be cleaner and easier to pep the lines in. I'll give you a (textual) peek at how I'm going to do it. Cardstock and mat board cut very easily (like butter when using a new blade). I already have the forearms marked up where the lines will be cut (it's so nice to be doing "regular" pep again). Mat board sections will be glued to the inside where the lines are marked. These strips will be the width of a trench plus about 3-4mm per side for sidewalls. Then the line will be cut in from the topside, one polygon panel at a time (so the piece holds its structural integrity). Lastly, each section will get a trench "floor" glued in from the backside before cutting the next section's trench. Easy. You'll see the result when I get photos up.
 
I've started pepping in what I'll call "separation lines" into the forearms and I think they're turning out pretty good. They're 1.5mm wide (which is conveniently also the thickness of mat board, so it can be used for spacers) and their depth is also the thickness of mat board.

Forearms12.jpg



Wrapping around to the forearm's inside, I've modified the parts to include a missing indent. First, I sketched it in referring to photos, then refined it with symmetric measurements and straightedge:

Forearms13a.jpg



Then I cut them apart on the marked lines and glued the halves together:

Forearms13b.jpg



Next I glued mat board strips along the cut edges to create the indent's sidewalls and continuation of a stepped line being added around the upper portion of the forearms:

Forearms13c.jpg



Then the two layers of mat board were glued together:

Forearms13d.jpg


Forearms13e.jpg



Lastly I used scrap mat board and cardstock to secure the indent's "ramp" in place:

Forearms13f.jpg



And here's the finished modified part ready for attaching to the forearm:

Forearms13g.jpg



The tabbed sides aren't completely glued together yet because they still need to interface with the other forearm tabs, and gluing all the mat board down will obstruct their assembly. I know it's a hack job but the intended look is achieved and they'll be cleaned up better later during finishing. More photos to come as I work my way around to the elbow cap...
 
That detail you're working on now is what I'm missing on the forearm model right now. I may have to use what you make as reference for mine lol. It's looking great btw. I can't wait to see this piece when it's done.
 
Thanks. But keep in mind I'm not putting much effort into exactness (like taking measurements from photos and scaling them). My parts are for a kid's costume, so although they aren't made precisely to scale off the game model, from 5 feet away they look like an exact match and ultimately that's all what really matters for costuming, and especially at this scale. If I were doing an adult build I'd be a bit more diligent with measurements.
 
The tabbed sides aren't completely glued together yet because they still need to interface with the other forearm tabs, and gluing all the mat board down will obstruct their assembly. I know it's a hack job but the intended look is achieved and they'll be cleaned up better later during finishing. More photos to come as I work my way around to the elbow cap...

I laughed a bit when I read the part where you referred to your work as a hack job. Your "hack job" is probably better than 90% of the stuff out there. I would be very interested in seeing one of your full size projects as a build log.

Amazing work Robot!
 
I call it a hack job because I only spent about an hour on it and didn't take any measurements from photos - just eyeballed it and slapped something together that looks about right because I need to pick up the pace on this build. Other people pep an entire armor set in the time I spend making just one piece, and I don't want the thing outgrown before I even get it completed. I do hope I've got the sizing right this time for fitting him next autumn.
 
All the pepped lines are completed on the right forearm and all that's left on it is finishing off the elbow cap. The left forearm is a couple days of work behind the right one.

A laser was used to locate the ending of a "V"-shaped ridge along the insides, so both top edges are level with each other:

Forearms15a.jpg



After marking the ridge's ending edges I cut it open along the marked lines:

Forearms15b.jpg



Then I again glued mat board to the raised half of the line and then a wider piece for securing the lower section:

Forearms12.jpg
Forearms14.jpg
Forearms15c.jpg
Forearms15d.jpg



The pictures make things looking a little crooked, but that's just due to the angled cardstock edges and a 2D/"flat" photo. They're much straighter in "3D".
 
Looking great! It looks like I'll have to get back to work on the forearm model since I'm done with the torso files. I can't wait to see what you do with the other files.
 
Thanks! When I rebuild the shoulder to my new scale for a 10 year old I'll be using your modified files since they have the outer arm indent modeled in and they were a pain to do freehand. And I too can't wait to show off what will be happening here with your torso files. But, to keep the kid interested, a helmet is next on the list after I re-pep the handplates and shoulders. Any chance of me getting your modified helmet model? I don't care if it's unfolded or not 'cuz I can do that myself.
 
Thanks! When I rebuild the shoulder to my new scale for a 10 year old I'll be using your modified files since they have the outer arm indent modeled in and they were a pain to do freehand. And I too can't wait to show off what will be happening here with your torso files. But, to keep the kid interested, a helmet is next on the list after I re-pep the handplates and shoulders. Any chance of me getting your modified helmet model? I don't care if it's unfolded or not 'cuz I can do that myself.

I was planning on going back and changing some of the depths on the recessed detail before I released it. Most of it just doesn't show up as well when it's actually built. If you still want to give it a go as it is then I can upload it and send you the link to it. It is unfolded, but I know that most of it will probably have to be changed lol.
 
Yes, I'd like to compare it against the flyingsquirrel file that I was intending to build. Recessed detail depth doesn't matter to me because I won't be using the pepped lines in the file (I like to add my own with sturdier mat board). What appeals to be about your files is the corrected overall shapes of the parts. If you're not ready to upload the helmet yet, that's fine - I still have arms to finish up yet. I wanted to get an early look at it though to start planning the build in my head while working on the arms (I always work in my head several steps ahead of the steps actually being built). Maybe you could pm a link to me if you're not ready for it to be public?
 
Yes, I'd like to compare it against the flyingsquirrel file that I was intending to build. Recessed detail depth doesn't matter to me because I won't be using the pepped lines in the file (I like to add my own with sturdier mat board). What appeals to be about your files is the corrected overall shapes of the parts. If you're not ready to upload the helmet yet, that's fine - I still have arms to finish up yet. I wanted to get an early look at it though to start planning the build in my head while working on the arms (I always work in my head several steps ahead of the steps actually being built). Maybe you could pm a link to me if you're not ready for it to be public?

I could do that. I don't think much of the overall shape was changed on the helmet. I think most of the changes were grooves around the brim and the center in the back. I send you the link as soon as I upload it.
 
Thanks - got it. I'll take a look at them when I'm back in PC-land (I avoid going there as much as possible). It will be a few weeks before I get started on a helmet.
 
Christmas has arrived partially early to our house this year. Wife thought it unfair to have most of the break from school with a 360 idle under the tree, so it's been set up and my boy played Halo CE for the first time tonight. He loved it, but why mention this in a build thread? I thought you might enjoy the humor in hearing about the wussiest Spartan in the cosmos! I swear, whenever there is the sound of Covenants or gunfire, this little Spartan runs the other way and hides. Crouching behind crates, cowering in alcoves…it's really pretty funny to watch - UNSC guys hollering for help and Master Chief is shaking in his boots hiding until it's all quiet again. I'm sure he'll get bolder as he plays, but this first time was hilarious. I'm anxious for him to open up the H3 Legendary Edition on Christmas.

As far as the build is going, one forearm is done and ready for resin - which isn't happening at a temperature of 9° so pep will trudge along until spring. Most of the difficult stuff is done on the second forearm and I'll get photos up of them together when the second one is done.
 
Oh my goodness, the picture you painted had me laughing so hard! Funny stuff. Our first Halo to play was H3, and we didn't get to play CE until recently. ^^ My oldest commented on how differently Cortana looks between the games.

I admire your patience with the pep work you do; it's always so meticulously done. Anxious to see your suit as it takes each step toward the finish line!
 
MOTHER OF HALO!!!! O_O You sir, have the serious guts, patience and skills to do HD pep like that. Normal tiny pieces already drove me crazy -.-*. Can't wait to see more, keep it up! ~_^
 
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