SirDigby's Halo 4 MC Foam build

[ChickenCeaser]

Hello 405th!

My names Curt, a college student from Arizona, and am currently in need of a costume for next years Phoenix, and hopefully San Diego, Comic Con. So naturally I looked to my all time favorite game series, Halo, for inspiration. I feel as though I'm a perfect candidate for a set of Spartan armor(being 6'6'' and 200lbs) so through some research on the web, here I am.

I've learned enough about techniques and materials through research, and all I need to start is some foam pep files for a Halo 4 Master Chief. As soon as I find those I plan on starting. Looking forward to it, and expect loooooooooots of photos as I progress.

 

[ChickenCeaser]

So I am about to go buy my supplies today. I was looking at this hot knife, but it says its for woodburning. My question is can it be used for EVA foam as well? I see no reason as to why not, but I thought I'd check.
http://www.homedepot.com/h_d1/N-5yc...&keyword=hot+knife&storeId=10051#.UN31km_AeKc

 

[DBmike]

Lots of people use them. Personally I favour the craft knife but each to their own!
Good luck. Looking forward to seeing it

 

[ChickenCeaser]

Well scratch that, theyre out of stock. Looks like I'll just be going with an exacto knife for now.

 

[vargatom]

I tried a hot knife as well, but I didn't like a couple of things:
- it burns the foam slightly which releases some fumes, that's certainly not good for you (respirator?)
- it also makes the edges slightly melted, so the sharp precise edges that I can get with a sharp x-acto knife are not possible
- it's very hot so it's a real hazard and you really have to be careful using it; unless you like to set your place on fire...

There are some good things about it though:
- no need to buy replacement blades
- can be used to burn in detail lines and circles and such
- can be used as a regular soldering iron if you want to add lights, fans and such

Also, if you get an x-acto knife, buy a 100-pack of replacement blades at the same time. Much better than having to stop when you run out of a 5 or 10 pack, and cheaper by the piece too.
Some people suggest sharpening the dull blades, but I've found that a new blade costs just a few cents in that 100-pack, whereas the sharpening tools and the time spent are actually more expensive altogether

 

[ChickenCeaser]

Whats a good thickness for the foam? I think the kind I bought might be too thin.

 

[vargatom]

I use 10mm as the base for practically every part. This is the interlocking floor mat EVA foam, 60x60 cm - it's reasonably strong to work without any additional reinforcement, although some pieces need an extra layer for support.

Then I add 4mm and 2mm craft foam pieces to layer additional details. Check Bradinator's work to see how it looks in practice:
http://www.405th.com/showthread.php/39000-Team-Impact-H4-Builds-(RECON-WETWORK-WARRIOR)/page4

If you're using pep files you need to work this out in Pepakura Designer, what to build out of 10mm and what to use craft foam for. If you're freehanding, or building your own templates, you can plan everything with the various thicknesses in mind from the start.

But you should definitely get 2-3 packs of 4 pieces of 10mm foam mats, that way you can also afford to rebuild a few pieces. It's pretty much expected to mess up on your first few parts - I've rebuilt some pieces two times util I was satisfied.

Also, I'd suggest checking the video tutorials from Drack and the threads from him and from Roxy and LilTyrant... Need links or can you find them?

 

[DBmike]

Whats a good thickness for the foam? I think the kind I bought might be too thin.

My reach suit is made from 12mm foam, I think...
And the IronMan build of mine is made of 8mm foam.

My opinion is this, the 8mm foam is better to work with, easier to shape and gives cleaner and more detailed results. Down side is it has less rigidity. But that can be improved by plastic coating the foam in RD65 or just accept the flex which tbh isn't a bad thing!

I may put together a video detailing the differences between the foam thicknesses coz this is a common question, but i'm sure you get the idea; thick is as good as thin its just down to preference lol, just ask yourself do I want a suit that can take a beating in a crowded environment or one I can make flex as I move?

so not a helpful conclusion but hopefully an informative one!

manoeuvrability over strength, if anything you want the first because theres nothing worse than being stuck rigid for an extended period!

 

[ChickenCeaser]

So I started my armor tonight and decided to go with a forearm to begin. The biggest obstecle I had was getting all of my cuts to line up, I feel that with foam there is a lot of room for error.

Oh yeah, I ended up going with a more Halo 3ish Mark VI armor, since I couldnt find any files for a Halo 4 foam helmet.

 

[RTWHOCKEY]

...college student from Arizona, and am currently in need of a costume for next years Phoenix, and hopefully San Diego, Comic Con...

Arizona, eh? What part? I live there too, Scottsdale area. A few friends and I plan to do to Comic Con too, so maybe I'll see you there.
Great build btw!

 

[ChickenCeaser]

I'm down in Tucson.

 

[vargatom]

I'd like to suggest watching Drack's videos, especially the tips on how to use the glue gun and how he does his cuts:

http://www.405th.com/showthread.php/37261-Foam-Technique-Tutorials

 

[BagelMaster47]

DARN, I'm too late. well if you still want to do halo 4 master cheif, then i edited a file for the helmet. and if you need them here is the page with the h4 mc files.
helmet:http://www.4shared.com/file/c91gBB3g/Foam_halo_4_pre_helmet_harnor.html?

other files:http://www.405th.com/showthread.php/34303-Halo-4-Pepakura-(Files-within)/page77

i would REALLY like to see some more h4 master chiefs on the 405th

 

[ChickenCeaser]

Thanks for the link. This first attempt was just a practice, I've been watching a lot more tutorials, and plan on retrying after work tonight.

 

[ChickenCeaser]

DARN, I'm too late. well if you still want to do halo 4 master cheif, then i edited a file for the helmet. and if you need them here is the page with the h4 mc files.
helmet:http://www.4shared.com/file/c91gBB3g/Foam_halo_4_pre_helmet_harnor.html?

other files:http://www.405th.com/showthread.php/34303-Halo-4-Pepakura-(Files-within)/page77

i would REALLY like to see some more h4 master chiefs on the 405th

All right you've convinced me. It looks like the only thing I'm missing now are the foam files for the calves. Know of any?

 

[BagelMaster47]

All right you've convinced me. It looks like the only thing I'm missing now are the foam files for the calves. Know of any?

there is a post by CoolC with most of the files that you will need.
below that post there is a post by rainbow dash with the codpiece, boots, and shin, files. hope this helps

 

[ChickenCeaser]

there is a post by CoolC with most of the files that you will need.
below that post there is a post by rainbow dash with the codpiece, boots, and shin, files. hope this helps

Whoops, I meant the thigh pieces. There dont seem to be any there.

 

[BagelMaster47]

Whoops, I meant the thigh pieces. There dont seem to be any there.

i am currently working on one the thigh, i should have it done in a few days. shouldn't be long unless you plan on starting with the thigh.

 

[ChickenCeaser]

So I did another practice run with a Halo 4 forearm, and the it came out much better. My gluing process has improved, and the only problem I'm having so far is predicting what angle to cut the pieces at. I end up having to recut many of them.

 

[ViperB77]

Hey Digby! I like your work! I heard using a hot knife, or finding a knife that can has an electric warming element in it, will aid in your cutting. Also, I thought if you cut with the knife held at angles of 45o to your incision line would help. Just a suggestion...