- Print out several views of the Master Chief character so you can see the shapes of his body armor clearly. Cut out the armor piece shapes in cardboard. For each of these, you'll cut out fiberglass fabric large enough to cover the cardboard shape and wrap around to the back. Using hot glue, attach the fabric pieces to the cardboard shapes. In a well-ventilated area, mix the fiberglass resin. Note: the resin will produce toxic fumes so be sure to work in an area with lots of fresh air. Mix the resin according to its provided instructions. Apply the resin to the fiberglass fabric covered pieces. Allow the pieces to dry overnight. The resin will be very sticky. You may wish to wear gloves while applying it.
Drill in any holes, or other details, to enhance the piece's look and make it more like the image from the game. Now paint the armor with primer and allow it to dry. Then paint your armor with its final color. Rustoleum deep green, hammered finish works well.
Attach the armor directly to knee and elbow pads. Use the Velcro straps to secure the knee/shin and elbow/forearm pieces around your lower limbs. Attach the remaining armor pieces either directly onto sweatpants and a sweatshirt. You can use double-sided sticky Velcro. - Salvage from a couple of old helmets. Use a bicycle helmet as the base. For the faceplate, salvage it from a yard work safety helmet. To make the faceplate yellow, glue on yellow cellophane. To shape the helmet, use cardboard and hot glue to create the various modular shapes seen on the Master Chief figure.
Once the glue has set, the helmet will be spray painted to match the body armor. Optionally, you can wire in some LEDs (light emitting diodes) with battery sources and toggle switches and attach them to the sides of the helmet. Or, you can paint on colored dots to represent these lights.
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