Halo Mk VI Master Chief w/ Weapons (WIP)

[Flagwaver]

After a couple of years of trying to actually find the time to do various costuming projects that I have been talking about, I have decided to just drop everything and start my Halo project. By dropping everything, I kind of mean that literally. Four Star Wars costumes, a Bleach costume, a Briareous, a Batou, and an angel are as of this moment in a series of plastic bins sitting in a deep and dark corner of the closet in the back of the house.

Right now, I have a plan. That plan is Master Chief. Not just a Spartan, but the big guy himself. That includes a M6G Magnum, a MA5C Assault Rifle, two M9 HE-DP grenades, a Mk VI Spartan Armor, and a Mk VI Body Suit, in that order.

The material I will be doing most of my building out of will be 1mm, 2mm, and 3mm sintra (also known as PVC foam board). If it is good enough for Mandalorian Armor, then it is good enough for a Spartan! To strengthen and help detail it, I plan to use bondo and smooth on. No resin or fiberglass, just good old bondo, sintra, and lots of CA glue.

The first thing I will be making is a maximum-detail M6G using a 1mm sliced file that I will be designing myself. This Magnum will be super detailed. As in, I plan to actually etch in the serial number and manufacturing stamp. It will have a removable magazine that is held in with a magnet, it will have a spring-locked slide, a spring trigger, and the entire left outside plate will cover a bunch of magnets (to lock it against my thigh armor). Not to mention, the magazine will have a faux round on the top, to make it look realistic.

Next up will be a 1mm sliced MA5C. It will be mostly hollow to hold the electronics necessary for the LED light system. The magazine will be magnetically held in the magazine well and will contain the same type of faux bullet as the pistol. The slide will be spring loaded and will cover the battery pack and on/off switch. Finally, it will have a series of magnets on the side to lock it against my back (just like in the game).

Finally, weapon-wise, I will be making the two M9s. I plan to make the template for them, myself. They will be just as high detailed as the other two weapons. They will include a pair of Chicago screws in the side to hold them to the opposite thigh as shown in THIS IMAGE

With the weapons finished, I will be building the HD version of the Mk. VI Spartan Armor. This armor will be higher detailed and will include screen accurate on-model weathering (such as bullet dings and melt-spots). It will also include the necessary lights on the helmet (both shield lights and the bright quad-spotlights) and body. This version will also have the necessary magnets in the right hip for the pistol, screw holes in the left hip for the grenades, and magnets in the back for the rifle. The underside will be padded with black EVA foam to be more comfortable, more forgiving to the under suit, and insulate the body from the electrical system. Finally, it will have a full voice amplifier and fan system in the helmet (possibly with the voice amp behind the chest plate).

In the end, after my body is more in-line with that of what a Spartan should be (starting the P90, P90X, and Insanity training programs now), I will tackle the under suit. It will be made using pleather, spandex, and other necessary materials to make it look like I just walked out of the game. After having worn a full Darth Vader (leather body suit), I know how to properly ventilate under hard armor while giving the normal appearance between armor sections. Not to mention, how to make the suspension system blend into the under suit.

And that is the end of the dreaded WALL-O-TEXT™!!! I’ve already began making the file for the pistol and will be sharing it in the next post. This thread will be a complete WIP, walking through the entire build process in case someone is crazy enough to want to copy my methods. I mean, that’s what WIP threads are for, right?

Wish me luck!

Then again, Spartans make their own luck.

 

[Flagwaver]

Well, part one down for the M6G Magnum. Using wizardofflight's blueprints on 405th.com, I have recreated the M6G in my CAD program. It looks a little more detailed than you are seeing below. However, I'll post what I have when I have it. Now, it is time to slice it...

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The Magazine is now drafted out. While it might look like it is normal magazine-shaped, it is not hollow in the middle (I just abhor dotted lines for hidden details). The only hollow part of the magazine is the very top. The reason is that I plan on getting a couple of resin copies of one of my .50 caliber Desert Eagle rounds to fix into the magazine. That way, when the magazine is pulled out, it looks like it actually has ammo.

The oval and circle details will not go all the way through, but I am going to try and shape the layer under them to look like more rounds. Also, there is a void in there for a magnet that is not shown.

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Well, the slide is completely drafted out. You might notice that the rear is missing some crucial little details. Those will be made separately and attached after. I hope to have it completely sliced tomorrow.

And yes, my CAD Fu is strong, grasshopper. Oh, and the entire weapon will be 10.5 inches long. Well, actually, it will be 26.7 cm long. However, it's late and time for bed.

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I reworked the slide a little to add some more details.

I added the rear details and made that just a straight slice through the rear of the pistol. Also, I aligned the inner part of the slide to be 3mm (1/8") thick where it rubs against the receiver.

Now, the explanation. The little pieces on the top of the first two pages is the sliced rear details. That little dot is the screw on the top center of the slide. The square piece and V on the first two pages are actually the rear sight.

If I do decide to take this into the M6X style (thanks for the idea Carpathiavh99), I'll keep it true to the style and even make the sight picture line up! (Sorry, I was an armorer for five years in the Army, I'm kind of picky about those sorts of things).

And now, to move on to the main body... ... ...

More to come SOON™!


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The receiver is now completely drafted out. I have still not "cut" down the action (where the slide slides against the receiver). I plan to do that after work this evening. Then, I will make the necessary changes to the slide and begin slicing the receiver. I should have everything ready to be printed by this Friday!

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Sorry for the double post, but I was either inspired or I accidentally used my wife's espresso mix in the coffee pot this morning.

Either way, I have detailed the inside of the pistol a little. I plan to do more, but it involves gutting it down so you can see the top of the magazine and the bullet when the slide is pulled all the way back. That will cut down on some of the weight that the sintra will have. As with a normal pistol, when you pull the slide to the rear, you will see the top of the magazine and the next round. This is a good reveal for the inner workings, too. Heck, I might even just keep the trigger spring visible to give a little more detail.

As you can see, there is a hole in the rear of the barrel, but it will not go all the way through. Like the front of the barrel, it will go no further than an inch into the weapon. This is for stability reasons. I don't like the idea of the center part of the front sight shroud held on by the sides alone (especially since the left side will be compromised because of the magnets I will place in it for the holster effect).

The rear block is about an inch thick (24mm) and will include a nipple for the spring. However, I need to get the proper spring before I can really draft out that piece.

Finally, there are a pair of guides on either side to make sure the slide doesn't slide off track. I might add a rail on the inside of the slide (and on the guides) to keep the slide down when pulling it back. Like a normal automatic, you will need to pull it all the way back to remove it from the receiver. I'll figure it out, though.

After all the training the Army gave me regarding my armorer skills, I figure it is a good base for building weapon props. If nothing else, this will be the MOST realistic M6G Magnum pistol in the world... at least until someone finds a way to build one that actually fires...

Hmm... now there's a project...

On that note, tonight I will mod the slide and then begin the final stages of slicing the pistol!

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Thank you. As long as I have at least 2 views of something, as well as a good angled shot and at least one measurement, I can make almost anything in my CAD program. I suck at 3D, but with 2D, I know my stuff (thanks to 4 classes at community college dealing with drafting, sight drafting, and CAD art).

Thankfully, I have today off. I think I should be able to slice the receiver today. That is, if it stops being insolent like it has been. I had to do a little more fine-tuning in the separation of the receiver. Hopefully I can do it without issues with what I currently have.

So, time to crank up my Halo soundtrack collection and get to work...

Oh, I already sliced the laser sight, the two knobs on either side of the sight holder, the end of the barrel, the magazine eject, and both of the slide lock levers. Those grooves you see on top of the internal portion of the receiver are just some details and have no real use other than to make it look better. Though, I plan to change it a little and add in a detail pointing toward the right hand side (where the rounds would typically eject). Also, this doesn't have the hole in it for the top of the magazine to be seen, yet.

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31 pages. 31 pages for a 1mm sliced M6G Magnum. It is done.

Now for the fun part. Well, the fun part will begin once my sintra arrives.

You might notice that the actual pistol grips are in several different pieces. Well, the reason is that the magazine can be seen through the opened slide. Unfortunately, because of the magazine, there is no room behind the trigger with the removable magazine. So, I have decided to make the trigger static and just tell people the weapon is on safe (if they ask).

I also went through and added my magnet holes to the design.

First, I placed a 1/2" x 1/8" magnet hole into the magazine and a 1/2" x 1/16" magnet hole in the receiver. The magnet in the magazine will be a 6.6 lbs and the one in the pistol will be a 3.7 lb. Both are separated by 4mm of sintra. One layer inside the magazine well and three on the magazine. That is so it won't have that strong of a pull. However, it will be enough to keep the magazine in the well until it is actually pulled out.

You might also notice the ten 1/4" cubed holes on either side of the pistol. I do not plan on cutting them all out, but the ones I do will be used for magnets. The magnets will be 5.5 lbs and pull through 1/4", but they will be used to hold the pistol against the thigh armor. The reason for both sides is in case someone wants to dual wield with one on each thigh (mine is only on the right).

 

[Flagwaver]

Okay, quick update. My sintra will be arriving on approximately the 24th. That leaves me with 6 days of nothing to do. That will eventually drive me more insane than Cortana in the most recent episode of Forward Unto Dawn. So, I have decided to start drafting out the MA5C.

 

[Flagwaver]

Well, the sintra came in, but now the print shop I use tells me that they don't do the adhesive paper anymore. Wonderful. So, it will be Friday before I am able to really begin this project.

 

[Flagwaver]

Got bored waiting for my next paycheck and decided to use the time to make a graphic to show my progress on the first page. However, here is a little preview for you with my current status... Look at the top of the page to see it.

It's amazing what you can do in CAD when you are bored.

Also, I have a timeline planned out for my projects. I'm splitting it into two periods per month.

Nov-1 - Build Pistol.
Nov-2 - Draft Assault Rifle
Dec-1 - Build Assault Rifle
Dec-2 - Draft Grenades
Jan-1 - Build Grenades
Jan-2 - Build Hands
Feb-1 - Build Forearms
Feb-2 - Build Biceps
Mar-1 - Build Boots
Mar-2 - Build Shins
Apr-1 - Build Thighs
Apr-2 - Build Waist
May-1 - Build Chest
May-2 - Build Back
Jun-1 - Paint armor & commission body suit
Jun-2 - Wire electronics and finish armor

 

[Flagwaver]

Okay, I'm back and running. Purchased the 8.5x11 label paper and got it all stuck to the 1mm sintra this afternoon during my lunch break. I began cutting out the pieces this evening, between answering the door. I guess the Zombie apocalypse is happening, because I was able to take out 15 tonight. I am just wondering why they all had candy...

Just kidding.

In this picture, you are looking at my pistol. On the far right is the first page worth of parts. Technically, it is three layers. You will notice that the round parts of the barrel as well as the squares are not cut out. The reason is that my ecaxto knife had no tip (it broke when I was working with the 3mm sintra on the previous attempt).

Beside that is page 2. I have the first half cut out and am now cutting out the trigger and trigger guard. Above it is the next part of the slice (still not cut out).

Finally, the remaining 29 pages of 1mm sintra.

Oh, and the exacto knife that has already tried to rebel and kill me. The blade snapped off at the base and would have skewered my finger if it had a tip (HA! THAT SHOWS YOU HOW MUCH EXACTO BLADES PLAN THEIR ASSASSINATIONS!!!)

So, tomorrow, after I find my replacement blades, I'll be cutting out all those little squares and finish the page (and the remaining pages). I also plan to begin lightly sanding down the lines to the edge (you can't really see the lines on the papers, but they are there).

Okay. Happy Halloween! That ends this issue of the WALL-O-TEXT™!!!

 

[Flagwaver]

Second update and 7 pages down (working on the 8th one now). Tomorrow, I am planning on buying a padded grip for my exacto... ouch. However, things are progressing pretty well now. Almost 1/4 of the way done.

On the left lower, you can see the detail visible on the grip with the open slide area. The very top part includes a part of the inner workings. Above that is part on the internal. The little "hole" in the rear is the part of the barrel that you can look at when you pull the slide back when it is put together.

Those little backward sevens are the rear of the pistol grip where the magazine is inserted. Below those are the more of the internals and the forward grip. The reason for the opening is so you can charge the slide back and see the bullet in the top of the magazine. On the bottom is the central part of the forward, including the central part of the trigger.

On the far right is the outer part of the receiver with a hole for the magnet to hold the magazine in. Below that is the opposite side of the forward portion of the receiver with the external of the trigger.

I slipped a couple of times and nicked off more than I wanted to. So, I will definitely need to use some filler. Otherwise, my two hour lunch is almost up and I will be continuing after I get back home after work. Yes, I can work that fast when I have the appropriate motivation (and massive amounts of chocolate for the sugar high).

Driving on, driving on. That ends part one of the November 1st issue of the WALL-O-TEXT™!!!

 

[Knighttoknight]

I can not wait to see this all unfold together looks really good so far dude.

 

[cooter1341]

Exciting, I am looking forward to seeing what you produce, it actually sounds like you know what you are doing and have a very good plan of attack on how to take it from idea to completion. Please keep updating us on the progress, this looks like an exciting build.

 

[Flagwaver]

Progress Update: 11/3/2012
Current Status: Phase I Pistol Cutting ... In Progress (60% Complete)

18.5 pages down, just 2 more to go for the receiver (13 pieces), and 12.5 more for the rest of the pistol.

So, I say this is the Phase I version because I am planning to build a Phase II in such a way that it can be produced with resin. It won't be the M6G, but instead the M6X (thank you carpathiavh99 on 405th.com). Let me explain.

The receiver and slide will be relatively the same as you see above, but it will not include the sight. Instead, it will have only an iron sight. The slide will be cast in one piece and the receiver will be cast in two, hollow for the inclusion of possible electronics. It will also have a separate trigger mechanism that can be moved. I will make the slide-lock bar actually work to keep the slide back. Finally, it will include a spring-locked magazine release button.

Now, for the fun part. There will be two separate pistol grips: Army and Marine variant (Reach vs CE). Each grip will include its own magazine variant. The grips will attach to the receiver using a magnet and a pin or two through the receiver (like an actual pistol). The magazines will have a faux bullet on the top that is spring-loaded so you can push it down (just as with a true magazine).

After that, I will make the top-mounted flashlight (LED light), the bottom-mounted laser sight (red pin-point LED since most places look down on actual lasers), and a suppressor that fits over/in the barrel. All of these items will be held on by magnets.

My ultimate plan is to have a small sound card and LED put in it so it flashes and gives the report with each trigger pull. Maybe going as far as giving an empty sound after 12 shots until you remove and reinsert the magazine (cutting and restoring power to the sound chip, resetting it). But, this is still a ways in the future.

 

[Flagwaver]

Progress Update: Supplemental
Current Status: Phase I Pistol Cutting ... In Progress (66% Complete)

Yes, yes. I know that double-posts are looked down upon, but I had an intense burst of inspiration (read: C-O-F-F-E-E). As you can see from the above shots, I did a little more cutting. But, that is not all...

The half on the left is the outside of the pistol while the one of the right in the inside.

I haven't got the details or holes drilled into it yet, and it is really rough around the edges, but it is complete. See the little bit of space just over the edge where the slide goes? Those are guides for the slide, which will have a lip to go through there.

Here's the magazine well and the barrel cut out (from both sides).

And now, for a thing of beauty...

Now, some of you may say that it looks really thick. Well, it is. While it is 32mm thick, it also has adhesive photo paper stuck between each slice. That stuff is about half the thickness of cardstock. So, it will slim up a little after I get the details cut into it and take the paper off.

Also, the void behind the trigger is where the magazine goes. Unfortunately, on this version, I don't know how to make the magazine fit with an articulated trigger... but I'll figure it out on the Mk II.

Finally, speaking of the Mk II, I would like to get it machine cut. So, if any of you have a laser cutter or a mechanical one that can take 1mm pages, you will score a free M6X package out of it... the whole thing, including SOCOM silencer. You'll get the 1st full pull of the molds! If you want in on this, let me know via PM. I'll even send you the 1mm sintra for the cutting.

Tomorrow, begins the slide! End WALL-O-TEXT™ II: Return of Text!!!

 

[Flagwaver]

Progress Update: 11/8/2012
Current Status: Phase I Pistol Cutting ... In Progress (71% Complete)

9 pages to go.

With the main body of the pistol completed, I am moving to the slide. It doesn't look like much right now, but it will. The biggest thing that I can describe is the two pieces on the bottom.

The reason they have two spines is that the lower is actually part of the slide lock. It is a little thin, but I will be fixing that for version 2.

More to come. From those who brought you WALL-O-TEXT™, I hope that you enjoyed WALL-O-TEXT LiTE™!!!

 

[Flagwaver]

Progress Update: 11/9/2012
Current Status: Phase I Pistol Cutting ... In Progress (74% Complete)

8, 8 pages left! Ah, ah, ah!

More slide. Nothing to see here. Just a small update. Being lazy on my day off.

This not WALL-O-TEXT™ is brought to you by WALL-O-TEXT II: The Sequel™!!! In a thread near you SOON™!!!