Go to the 501st forums for star wars armour, and the 405th for Halo, read 1000 forum threads there about exactly that, by everyone from professional propmakers to total bedroom amateurs. Learn, and copy.
>>750003 http://halocostuming.wikia.com/wiki/Pepakura_File_Index >choose armour >open with this http://www.tamasoft.co.jp/pepakura-en/ >print (I recommend cardboard because it's easier to work with) >assemble with superglue >fiberglass and bondo >fuck loads of sanding >paint and pad with foam
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