Redditor mawrTRON demonstrated his devotion to screen accuracy with his Halo Fred-104 costume by sharing the above photo. It’s a side by side with his costume on the left and a shot of the character in the game on the right. This is his third Halo suit build; he constructed his first suit over seven years ago. This costume marks his first attempt at replicating the outfit of a main character in the video game, and I think he pretty much nailed it.
He put a plan in place for assembling the costume before he got started. He explained:
I will be using pepakura and EVA foam for the body and pepakura and resin for the helmet.
Basically I will be building each part of the armor in perakura first before dissecting them and transferring them onto EVA foam.
Doing things this way allows me to check the scaling of each piece and see how the general shape looks. Its a little long winded, but it does help me nail down the scale.
The helmet I will be using good old pep, resin and bondo. Keeping it OG.
I thought about using a 3d print. However none of the 3d printed centurion files I have seen seemed accurate to me. Besides, the H3 rogue and H4 defender helmets I had made previously came out really well, why quit while you’re ahead right?
You can learn more about the creation of the costume and see additional photos in mawrTRON’s build thread at the 405th forums.