The Halo Master Chief Helmet was a project started in 2015 with a custom Pepakura file we commissioned to use for our costume. Made from 110lb cardstock, hundreds of pieces were cut, scored, and glued into place. Once the paper construction was done, the helmet was coated with fiberglass resin on the inside and outside. A combination of Bondo body filler and fiberglass resin was mixed to create “Rondo” a body filler that has a runny texture that can be slushed around in the inside to create a strong shell. Bondo body filler was applied on the outside to cover any imperfections. This was the most time-consuming part of the build as every detail had to be angled correctly while being completely smooth. Epoxy Sculpt was used for any raised details.
The helmet was molded using Rebound 25 silicone from Smooth-On and the mother shell was made from plaster bandage strips. The casts were made with Smooth Cast 65D rotational cast resin. Visors were vacuum formed over an Ultra Cal 30 buck.
We brought a painted cast to Halo Outpost Discovery where we got it signed by voice actors/actresses from Halo along with the development team.
This is still a work in progress project as we are preparing to re-mold this helmet in a new and improved way. Stay tuned for more!
Thank you for viewing, if you have any questions regarding this build, feel free to contact us!
