So, here we have it. My summer project that didn't actually become my summer project until the end of summer. As a result of that, this is as far as I can manage to get, since I'm moving back onto my university campus and won't be able to work on it there (requires use of toxic chemicals and respirators and such). So, I'm saying that it's roughly 80% completed.
The process of making the armor uses "pepakura" files to make the base out of cardstock (paper). Once that is put together, fiberglass resin and fiberglass cloth is used to coat it and strengthen it. Then, I used "body filler" to coat it again and paint it. I'll upload more photos detailing that process when I get the chance.
For now, let us laugh at my bad craftsmanship, my chest piece held up by duct tape, and the blue rags stuffed into the helmet to keep it in the correct place on my head. And the fact that I'm holding an M4 just for the sake of holding a weapon.Check out the 405th for Halo costuming resources and info if interested