One project that has burned into my mind ever since played the first HalfLife was creating a full size HEV suite. People have created full size ‘armors’ based on Sci-Fi characters before.

Specifically fans have created their own Storm Trooper, Boba Fett, Master Chief, Gears Of War, Deep Eyes, and recently, Iron Man costumes. These have all been created by fans with the skills or drive to gain the skills needed to realize the characters in the real world. I’m really surprised that no one has done a high quality HalfLife HEV costume. The HalfLife games have been so fantastic and have really influenced gaming in many ways. You would think that it would have been in that top list of geek-loved, fan created costumes.

I was actually going to go to college for a degree in industrial design and visual effects but switched my major a month before I was to start. I’ve always loved and studied ID and effects but have yet to do much with my knowledge since leaving school. Now that I have a 50’s era two car garage and work shop the nagging projects that have required space and messy have resurfaced. Since the HEV is a partial hard suite I’ll need to work out how to fabricate the hard armor portions of it. I’m currently working out the best, cheapest, easiest approach for it. At this point I’m not sure if that will be vacuum forming, fiberglass, slush molding, or resin molding. There are also portions of the suit, namely the belly and joints that would lend themselves to being created via covered urethane foam shapes.

If anyone out there has any ideas or tips on costume fabrication or specifically on fabricating Sci-Fi armor please share in the comments.