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Coolest Homemade Black Spartan from Halo 3 Costume

The main reason I decided to make this Homemade Black Spartan from Halo 3 Costume is because I am a huge fan of the Halo series. Along with many other kinds of costumes I have made, I have also made other Halo series costumes too. I have been making props and costumes for years now, and my skills have increased substantially.

How I made this costume is by using a program called Pepakura Designer 3. A lot of the costume is built from scratch too. I would say it is made from about 40% Pepakura, and 60% scratch build. If you haven’t heard by now what Pepakura Designer is, it is a program that takes a rendered 3D model and it breaks it down into shapes with corresponding numbers on them. You can then print these shapes onto paper, cut them out, and then glue them together.

After this, you should get the basic piece of your armour that you printed out. I then strengthened the armour by putting a light coat of fiberglass resin on the outside, used fiberglass mat with resin to strengthen the inside, and then used automotive body filler to smooth out the outside. The process for the scratch build pieces was to build them up out of corrugated cardboard, by looking at reference pictures to see what was needed to be done.

Then I used automotive body filler to smooth out the outside. After I did this, I resined the outside of all the pieces to give it a very interesting plastic type texture. I then detailed it with paint, (one coat black gloss paint) then I battle damaged it by spray painting a paint brush with chrome paint, and brushing my pieces lightly with it to make it look like worn metal.

And all of this was completed the day before Halloween. I hope I gave everyone a “basic” understanding of what it was like to build this Spartan armour.

P.S. I built all of the pieces by myself without assistance, this is my “own” work not somebody else’s.

Black Spartan Costume

Black Spartan Costume

Coolest Homemade Costume Contest 2023

7 thoughts on “Coolest Homemade Black Spartan from Halo 3 Costume”

  1. Depends… Ide have to go through the tedious and time consuming process of making another suit similar to this one and ide have to put down a good chunk of money towards it to do so. How much were you thinking of grabbing one for if I were to make another one? You can e-mail me with further questions at sc.estuff@gmail.com

  2. Its a visor that I ordered from a visor hat on ebay. I just cut out the part that I needed and glued it in. And I would like to be able to accommodate all of you kind peoples and form some sort of distribution line in which I could build a worthy version of the chief’s suit and throw out multiple casts for cheap, but this is just a simple suit made from cardboard and cardstock, reinforced with fiberglass and fiberglass resin and shmewthed out with body filler and body filler, filler, lol…

    Its not hard to do, the forums on the 405th have been gracious enough to post tutorials from people like me over the years, it just takes a lil tlc and a semi-decent chunk of cash, in which you peoples seem more than willing to spend on a suit that is sub par in comparison to what you could be spending it on. Create a masterpiece, be inspired, live your dream. If you still are un-inspired to do so though, and you would prefer to just purchase an already hand-made suit, I can see how I can accommodate.


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