Wednesday, October 6, 2010

HALO EVA Helmet Visor Project

When they came out with HALO3, the folks at Bungie included a lot of options for customizing the look of your armor in the game.  Among the many permutations avalable is the "EVA" version, shown here:

I think the helmet is pretty snazzy, even if the large gold dome would work best as a sniper magnet.  Still, I haven't liked it enough to spend the time building one from scratch. 

A while back I acquired a raw casting of this helmet in a trade with another maker.  The main challenge for this particular helmet though is to get the gold-tone, full-head faceshield to have the proper metallic sheen and still be transparent enough to see through.

I came up with this plan knowing it would not be perfect. I did expect it'd look the part though.  Here's how I went about it...

Step one, cut out the recessed areas:

Step two, cut out pieces of 1/8" amber acrylic, cook them in the oven until they're soft and flexible, and press them into the holes with a rag so that they become convex:

Step three, spray the helmet with black primer and test fit:

Step four, tack the acrylic pieces in place with CA adhesive and test fit again:

Step five, caulk around th edges with clay:

Step six, mask off the inside of the acrylic where you'll need to see through:

Step seven, pour a batch of black casting resin inside and coat everything:

Step eight, after the resin has started to cure and before it is fully hardened, peel out the masking tape to uncover the acrylic viewports:

Step nine, mask off the viewports, pack the edges with filler putty. Then, when the putty has dried, spray the visor gloss black:

Step ten, spray on a coat of Mirrachrome, allow to dry, and then remove the masking tape:

Step eleven, test fit:

Step twelve, wipe down the inside of the acrylic parts with acetone and/or rubbing alcohol:

Step thirteen, dry out and remove fumes from inside the helmet:

Step fourteen, lightly spray the inside of the acrylic parts with Mirrachrome:

Step fifteen, smile for the camera:

Step sixteen, test fit:

Step seventeen, spray on a coat of Tamiya "clear orange" acrylic:

The color looks about right in sunlight, but it loses a bit indoors:

Still, it seems to fit in with the rest of the stack okay:

Sooner or later, someone's going to ask about visibility. Here's a shot from the inside of the helmet:

The dark spot is where I put the Mirrachrome on a bit too thick. Otherwise, it's a bit cloudy but it works.

Step eighteen, mask off all of the metallic parts and spray on a coat of satin white paint (the primary color I've chosen for this helmet):
EVA Visor 19

Step nineteen, hand paint the brown portion (the secondary color I've chosen):
EVA Visor 20

Step twenty, test fit:
EVA Visor 21

Step twenty-one, hand-paint the black details:
Black details

Step twenty-two, sit back and marvel at what you've wrought:

Now I just need to find a very large friend with a very small head to dress up as the Meta from Red vs. Blue...


  1. Very cool! I was wondering tho, I can understand using clay to caulk the outside of the lenses so the adhesive doesn't leak through. But Doesn't the clay leave a wicked residue on the acrylic? How do you get it clean enough to paint?

  2. It does leave a bit of oily residue, yes.

    A great trick I learned from my latex mask making experiments though: oil-based clay cleans up easily with rubbing alcohol.

  3. where would i buy a gold visor because i am making a helmet

  4. how much would you sell and Eva helmet fully done?

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  6. i am acutally making a meta costume :D
    i bought the helmet kit, as i have an exrremaly limited amount of time.. and i am currently making the armor my friend shall cosplay texas and i am going to be the meta, i hope i am "tall" enough.. 180.. is not exactly huge...

  7. can i ask how a spray paint is see through. if i were to spray it onto perspex would i het the same result. can you explain? cheers

  8. I want to make a big, Avatar-Style face mask and mirror it. Can I ask if one would be able to stencil in black over the initial mirroring coat of mirrochrome?

  9. By the way, how expensive is a can of Mirrachrome, because I'm a cheap-ass and I want to make a helmet with a stencil on the outside.

  10. Where would I find where you show how to build the rest of the parts for this suit?