I am currently busy with a Mal Reynolds Firefly costume, but once I get some more funds together I am thinking of making a Master Chief outfit.
I do have a few questions though, as my build will need to be able to withstand a bit of a battering. I am planning to make a costume that can survive airsoft skirmishing (BB guns).
Firstly, I need to know a good way to comfortably and securely wear it. So far I think seperating each piece into two sections, padding them, and using a relatively tight elastic strap. On the undersuit, I will be adding padding to the areas not covered by the suit itself, with the added benefit that this should help stop any movement by the straps.
Secondly, what sort of strength does the polyurethane/fibreglass mix have? Can it withstand a bit of beating, or will BBs penetrate? If it helps, the max force the BBs will hit me with is about 2.5 Joules, although I will need it to withstand potentially hitting off walls etc as I'm trying to avoid being shot
Lastly, what should I use for the undersuit?