Follow the intrepid adventures of one loveable Bluetard, Caboose, and his faithful plushie Grunt companion, Geoffry, as they set off to go on adventures and see amazing things and things on fire and pretty things but mostly things on fire but we agreed that that is not anyone’s fault….
(Agent North is going to be a Halo 3 Mark VI, and the best method for making the Mark VI is going to be Pepakura.
Pepakura is a piece of Japanese paper folding software, that customers started to use for making costumes several years ago. Basically, Pepakura breaks down a 3-D model into a flat 2-D set up for printing, and then tells you how to reassemble back in 3-D. For a long stretch of time, the primary method of Pepakura for costumes was to fold the card stock paper, and then fiberglass the interior of the piece for strength and rigidity.
Recently there has been a swing towards the use of EVA foam for armor costumes, often using modified Pepakura models to get a handle on how to make, break down, and assemble the armor components.
The RPF has a fantastic knowledge base thread for Pepakura that can help someone get a good grasp on pepakura:
Also, now that they are under new ownership/management, and the new management is taking care to fix and update the forums so that you can actually register and post, I finally feel comfortable referring people to the 405th Halo Costuming Forum: