Michael Knell built an incredible costume for his 6-year-old son for Halloween this year. He turned him into Master Chief from Halo and built the costume from scratch. He spent about 60 hours working on the costume and used EVA foam and craft foam for most of the armor. The helmet was made from a pepakura file, and Knell added fiberglass to the molding paper to make the helmet durable. While Knell doesn’t go into a ton of details about each step, he did document the build with tons of photos. You can see all of them at Knell’s Flickr page.