How to Make a Cardboard Halo Costume


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

Things You'll Need

  • Reference image of Spartan-II armor
  • 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
  • Make the pattern for the armor using the poster board. Though the armor 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 armor.

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

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

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

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

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

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

Tips & Warnings

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


  • Photo Credit Alex L,
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