Ok so a while back I got interested in making some Halo Armor out of pepakura. I'm just now finally going to dabble a little bit with it to see if my friend and I like it or not. In the next few weeks we're going to make our helmets to see if it's very difficult (I'm expecting it to be). If we do it I will post pics from start to finish. Also if some of you could post some links of pictures of a halo 2 odst helmet that'd be great! (having trouble finding photos for reference.
Pepakura which is mostly paper mache. It involves printing out shapes on paper, folding and gluing said pieces together, then fiberglassing and adding bondo. My friend and I are almost done assembling the helmets and hope to be fiberglassing soon. I decided if this helmet doesn't fit I'm going to make casts and sell them and then try to make another helmet. If I do make another helmet it will probably be a Mark VI or a Scout.
I dunno. Add a few extra layers and you might be surprised.
If you have the inclination (and a pair of tin snips with a few extra dollars) you could always mold your body parts in plaster, then use cheap sheets of aluminum siding or plating as your base layer instead of card stock. It wouldn't stop a bullet, but it'd handle airsoft and probably paintball.
I am the Chozon1. And possibly, a booger head. They'll let anyone on Soundclick, apparently.