Bondo body filler was applied on the outside to cover any imperfections. A combination of Bondo body filler and fiberglass resin was mixed to create “Rondo” a body filler that has a runny texture that can be slushed around in the inside to create a strong shell. Once the paper construction was done, the helmet was coated with fiberglass resin on the inside and outside. Made from 110lb cardstock, hundreds of pieces were cut, scored, and glued into place. The Halo Master Chief Helmet was a project started in 2015 with a custom Pepakura file we commissioned to use for our costume.
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