How to Make a Cardboard Halo Costume

Written by matthew anderson
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How to Make a Cardboard Halo Costume
(Alex L,

Master Chief, the main character of the Halo science fiction game series, is never seen without his full Spartan-II combat armour. The armour's surface looks more like plastic than metal and has a variety of non-functional panels and protrusions. The full suit of black armour has larger, coloured plating over the chest, arms, legs, and head. You can make a cardboard version by using a black body suit covered with cardboard "armour" in place of the larger, coloured plates.

Skill level:

Things you need

  • Reference image of Spartan-II armour
  • Poster board
  • Cardboard
  • Duct tape
  • Sharpie
  • Scissors
  • Velcro
  • Black thread
  • Needle
  • Paint
  • Orange-yellow plastic for visor
  • Plasti Dip
  • Sponge brushes
  • Pen
  • Black sweat suit
  • Black gloves

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  1. 1

    Make the pattern for the armour using the poster board. Though the armour appears round at a glance, closer inspection reveals the sections are mostly made of smaller, straight edges placed on angles. The pieces should fit over the black sweat suit and gloves, which will be the base for the armour.

  2. 2

    Fit the pattern pieces together. Make any adjustments so that they sit right and fit comfortably on the black sweat suit and gloves.

  3. 3

    Cut the cardboard out in the shape of the pattern pieces.

  4. 4

    Duct tape the pieces of the armour together from the back of each piece to form the armour sections. Now you have sections to attach to your sweat suit with Velcro. Duct tape the plastic to form the helmet visor.

  5. 5

    Mark where the Velcro should go on the armour and on the sweat suit. On the armour, use the adhesive strips on the Velcro to attach it to your armour pieces. Sew the corresponding Velcro pieces to the sweat suit and gloves.

  6. 6

    Brush Plasti Dip onto the surface of the armour to form a smooth surface. Plasti Dip is a synthetic rubber coating that is applied like paint. This will give your armour the plastic appearance of the Halo armour.

  7. 7

    Paint the surface of the armour. Master Chief's armour is sage green, but other colour schemes can be used. Etch details into the paint to match your sample image.

Tips and warnings

  • Good application of the Plasti Dip surface can cover minor imperfections in the armour pattern and construction.

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