JUSTINIAN'S Halo Mark VI Build

JUSTINIAN · May 10, 2013

I have been wanting to do a Mark VI Master Chief build for many years now. Now I finally have a chance to do it. My deadline is for Dragon Con this summer, so I will have to do this pretty quick. I hope you enjoy the ride.

This is my first foam build, and from what I have done so far, I will be doing most of my future builds out of foam. I'm using a laser to cut out all of the parts, to save some time, and to make all cuts perfect. I am really pleased with the results.

Here is the first sheet on the laser.

All 3 sheets for the torso.

Here is the base of the finished torso.

I started with a low def file, and will add the small details later. This took a few days to do.

Thanks for looking.

Briciius · May 10, 2013

Re: JUSTINIAN'S Foam Mark VI Build

love it !!!

Take your time to add the details and you will get an awesome chest

Nico

JUSTINIAN · Aug 12, 2013

Thank you. It's time I get this thread back up and running.

Here is a bit of a teaser of something I have in the works. Can you guess what it is?

JUSTINIAN · Aug 15, 2013

No replies?
I'm 3D printing the helmet.

Update time.

Progress has been going much slower than I wanted. I'm using some foam templates, but then also adding a lot of my own details from scratch. I'm pretty happy with the end results. Hopefully it will have as much detail as a fiberglass suit. Here are the thighs.

Here is the cod.

My helmet has been completely printed. I should have it by the weekend. I'm super excited.

It's crunch time, so I really need to crank up the production. I need to have the rest of the suit built by the beginning of the week.

Camaro91 · Aug 15, 2013

Dang! I don't know how I missed this thread earlier but it looks beast so far. Super crisp cuts from the laser I am super jealous! Looks amazing, 3D printing your own helmet is looking good to.

Again I just cannot believe how awesome the chest and thighs look!

JUSTINIAN · Aug 15, 2013

Thank you. I actually had a friend 3D print the helmet for me. I haven't had a chance to get a printer yet.

Update time.
Wow, second update for the day. I hope progress continues like this.

I'll go into detail on these shoulders.

I cut all all of the parts for both shoulders.

I figured out where the bends are going to be, and beveled them out, but not all the way through.

Then I started to glue the edges together.

Then you get a part that looks very clean, like this.

Then I worked on the other sections.

Here are both of the completed shoulders.

On to build the next parts...

Camaro91 · Aug 15, 2013

Gotcha, I'm sure you'll get around to getting a printer sooner or later lol

But it's just phenomenal on how this is turning out!

JUSTINIAN · Aug 16, 2013

Thank you.

Update again.
Last night I got the forearms done. And can I say that I absolutely hate doing the forearms on any build. It took me about 5 hours to do just these.

This morning I did some tests with my paint. And I think I got it down pretty good. I will be using the same paint from my last suit. And with a little weathering, it completely changes the color to be what I need. The left one is just an extra FUD hand plate I had laying around, the right one is from my last suit, unweathered.

Let me know what you think.

Camaro91 · Aug 16, 2013

I know how tedious forearms can be and that's without good angles.

The color looks good and looks perfect when weathered

JUSTINIAN · Aug 19, 2013

Thank you. I am very pleased with the color. I will most likely do slightly less weathering though.

Not a huge update. I didn't get a chance to work on this at all this weekend.
Today I go the helmet in. And it looks absolutely amazing.

I did some minor cleanup around the edges, and super glued the parts together. They fit very well.

There were a few small gaps along the seams, so I did some rondo to help fill them in.

Then I did a coat of filler along the seams, and any spots that were kind of rough.

I was hoping to be able to get it sanded and put into primer tonight, but it is way too late. So I'm going to bed. I'll get more done in the morning.... well a few hours at this point.

Thanks for looking.

adam0918 · Aug 20, 2013

Just a question: what kind of glue do you use to put the foam parts together? And it holds well enough that it'll survive through some wear and tear?

JUSTINIAN · Aug 21, 2013

adam0918 said:
Just a question: what kind of glue do you use to put the foam parts together? And it holds well enough that it'll survive through some wear and tear?

Hot glue and super glue work great on foam. They both adhere well. Sometimes I will glue the parts together with super glue, and then reinforce the backside with hot glue.

Update time. I spent the last 3 days non stop sanding this bad boy down. It looks absolutely fantastic!

I'll let it dry overnight, and then in the morning the molding begins.....

JUSTINIAN · Aug 26, 2013

Big update from this weekend.

I spent the rest of the week working on the mold for the helmet. Here is the print layer of Rebound 25.

After multiple coats, the thickness is starting to build up.

Here it is with the support shell done.

I also got some boot made.

And some shins.

I also used some resin to strengthen some of the parts.

And the chest is now fully detailed.

Sealing and painting comes later today. Only 3 days left to get this thing finished....

Vinom11 · Aug 26, 2013

That's a stellar build you have going there. Looks very clean. Didn't see anywhere in the thread where you got these foam files from. I intend to redo my Mark VI in foam and your build is exactly what I am going for.

Camaro91 · Aug 27, 2013

Dang! That came out amazing!

JUSTINIAN · Aug 28, 2013

Vinom11 said:
That's a stellar build you have going there. Looks very clean. Didn't see anywhere in the thread where you got these foam files from. I intend to redo my Mark VI in foam and your build is exactly what I am going for.

Thank you. I took the basic low def files, and did some cleaner unfolding for foam. Then I brought the files into my graphics program and did a ton of additional detail work, by hand.

Camaro91 said:
Dang! That came out amazing!

Thank you.

I'm slowly getting there.

The plasti dip went on very well. I did 6 coats in 2 hours.

I also got a test pull from the helmet mold. I am very pleased with the results.

I also got the chest buckles done.

And as if I wasn't too pressed for time already, I made a mold for my hand plate.

One day left. I think I may need to pull an all nighter tonight to get this finished in time.

Camaro91 · Aug 29, 2013

That helmet cast came out amazing too, this whole thread is a bunch of awesomeness!

The Terminator · Sep 1, 2013

Pretty damn epic and real nice!

Will you continue working on this and making it perfect..?

JUSTINIAN · Sep 4, 2013

Thank you. I will get it finished.

Well, I made it just in time for Dragon Con.... Barely. But before I get to any of that, let me get you guys caught up on what I did.

I have had a few people aske me how to install a visor, so here are my steps... because I had plenty of spare time to make a tutorial lol.

Cut the visor section out of the helmet.

Get a gold visor (or whatever color you want)

Be sure to inspect it for imperfections. This one was defective, and the gold film peeled right off. This was going to be a tutorial for a double layer visor, but now it is a single visor.

Neatly cover the visor with tape, front and back.

Place it in the helmet, and draw a line where it goes.

Take it out and trim it to fit. I usually leave about 1/2 an inch around the line.

Put the visor back in place, and fill in any gaps with Bondo.

Let the Bondo mostly cure. While it is still a little soft, you can remove the visor.

Then sand down the bondo, so that it is completely flat with the helmet.

Test to make sure that the visor is a perfect fit.

Then you can peel the tape off, and glue it in place. I use some super glue to hold it down, and then use epoxy along the edges inside.

I also got my armor painted.

I will upload more pictures in the morning.

Camaro91 · Sep 7, 2013

Super excited to see how this turns out! Looks good already just laying around!

JUSTINIAN'S Halo Mark VI Build

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