Yes! 1:1 scale scratch building! I realize this isn’t exactly an aircraft, but since this is my usual haunt, please forgive my self-indulgence…
Halloween’s almost here, and to my utter surprise, my 15-1/2 year-old son (a Halo ace) still wants to trick-or-treat with his friends this year! So the other day, he’s in his room, with a cardboard FedEx box over his head (no surprise to me, since teenagers do weird things all the time). A little later, he comes in the office and asks if I could help him build a Master Chief helmet. And since the opportunities of ‘father-son’ projects are fading fast, I jumped at the prospect. I had no idea what I was getting myself into. Where to begin? No plans were available on the web, that was the first place I checked.
I got as many reference photos as I could, and set to work. Step One was to order up a motorcycle helmet shield, this would be the anchor of the entire project. Everything that followed was planned around the shield. A few rough patterns translated to cardboard cutouts, glued in place, every piece improvised, based upon photos. I realize there are discrepancies from the original Master Chief helmet, some artistic liberties were taken, but these were largely done for the sake of expediency and ease of construction. I can’t tell you how many times I almost simply admitted defeat. But too late, I already said I could do it, so I had to deliver.
Constructing the visor…

After adding details…

Now the decoupage newspaper (remind you of elementary school?)…

Finished product…



It’s all but done. I just have to glue in the foam lining. This was an all-consuming project, a nightmare created of cardboard, poster board, wood glue, and insanity. And I realize it’s far from perfect, and somewhat reminiscent of a Mexican piñata. But once again I am a hero in the eyes of my teenage son, and who can put a price on that?
Now if you’ll excuse me, I have to get back to building my life-size “Cortana” robot.
