Halo 4 foam armour build

[NeonHybrid]

So this year I plan to attend the London comicon in October. I already have a rather nice Recon helmet due in the next month.

My plan is to use foam to put together the armour but I'm not 100% on where to start with the design stage. I have watched enough videos and read a lot of posts on how to construct it but I'm struggling on how to produce each part without a template to work from. I have seen people working from pep files but I want to use the stalker chest and as far as I can tell there isn't a model for it. Normal I work with materials that if they are a little out I can just add a little filler and it's fine but I suspect that's not going to work so well with foam.

Any advice would be greatly welcomed.

 

[Lew Majestic 28]

I'm Building a halo 4 Spartan too mate and i was really swinging towards making a stalker chest for it ! I've been trying to find 3D models of it and renders and stuff but I've come up short ! I'll let you know if I find anything!!

 

[NeonHybrid]

So after searching for the stalker torso and coming up with nothing I am going to go with a full set of recon armour. For the arms I'm going with recruit and the legs will be RG-63 Counter. Unless some one wants to create a pep file for the recon legs that didn't make it into the game except for on Madsen in Spartan Ops.

I had a go at making the foam shoulder file but not only is it too small I find it isn't close enough to the actual design. So I will be taking the parer pep file and setting it up for laser cutting.
Depending on the length of time it takes to put the files together I will either have to cut the parts at a local work shop in Glasgow called MAKLab that rents out time on their equipment.

I have had a look for information on laser cutting EVA foam and it appears with a decent filter and extraction it's not a problem but if any one has experience with it I would appreciate any advice especially on what settings were used.