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How To Make Halo Weapons ⊕

Updated on October 20, 2012

Halo 3 Replica Shotgun Prop

This lens is all about how to make replica Halo weapons using the sliced foam procedure. It has no moving parts, so is very durable and simple to construct. For our featured Halo prop gun we will be making the shotgun as seen in Halo 3. If you've made a Master Chief costume or a Halo Reach suit you will need a weapon prop to go with it. A Halo weapon makes a great accessory for photoshoots, however, if it is a larger weapon it can get very heavy while posing, particularly when holding an extended arm pose, and that's the main reason we suggest using this sliced foam method to make your replica Halo prop.

How To Make Halo Helmets

Master Chief Coloring Pages

October 21, 2012

Foam Shotgun Version 1 Outdoor Photoshoot - Featuring Spartan Intimidator, Photos by Longshot-x

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Halo 3 Replica Weapon Props

The shotgun challenge

Are you ready to make your own Halo gun similar to the shotgun on this page? You will need to follow a few simple steps and have access to the correct materials and tools.

First step: is to make or buy the patterns and then print and cut out the shapes.

Second step: is to cut the paper shapes from 10mm foam mats or 3mm crafting foam using a hotknife. Each pattern shape will have 10mm or 3mm marked in pink.

Third step: is to detail and shape parts using a heatgun and hotknife as well as the burning iron and then glue them together with a hotglue gun. During the crafting process you will also be burning your details in to the foam with a wood-burning tool and installing optional LED lights.

Fourth and last step: is to spraybomb Plasti-dip or Krylon Latex coating and then paint it to your desired colors.

Note on our shotgun versions: Our first shotgun is a construction tester, we call it version 1. Version 1 has a flashlight but no other LED's and after handling it, comparing it to in-game Halo 3 reference pictures and taking it to a few conventions we worked out any problem areas, tweaked the patterns and made our shotgun version 2. For version 2 we strove for game accurate size and details, as well as blue LED's in the 2 sight panels. The patterns for sale are for building version 2.

Halo Shotgun Crafting Stage 1 - Prepare and print your patterns

Halo shotgun pattern
Halo shotgun pattern

This is a sample of our patterns for the Halo 3 Shotgun Version 2, there are 8 pages in total.

Legend:

Pink text - foam thickness

Red/orange line/circles - burn lines and 7mm diameter branding circle

Green circles - 6mm diameter branding circle

Blue line - outside 45 degree angle

Black line - shape outline

Yellow crescent - rounded shape area

Thick dotted blue lines - multi-page shape guidelines

Green arrows - point to a finish (exposed) edge, be sure to sand smooth

Triple grey line - 5mm V shape cut lines for barrel grip

One shape is marked "burn detail", you do not cut this shape from foam, instead use the shape as an overlay to burn in the detail lines and for proper placement of the small detail disks.

Foam Shotgun Version 2 Indoor Photoshoot - Featuring Spartan Longshot-X, photos by Dave

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If this room had a skylight... you might see it in the Chief's visor.The goal is to mount it to the back with magnets.Admiration...Greater admiration.Is that a grunt over there?You want a piece of this?I didn't think so.This is how a man reloads!Version 1 and version 2 - double trouble.You don't wanna mess with this Master Chief.
If this room had a skylight... you might see it in the Chief's visor.
If this room had a skylight... you might see it in the Chief's visor.
The goal is to mount it to the back with magnets.
The goal is to mount it to the back with magnets.
Admiration...
Admiration...
Greater admiration.
Greater admiration.
Is that a grunt over there?
Is that a grunt over there?
You want a piece of this?
You want a piece of this?
I didn't think so.
I didn't think so.
This is how a man reloads!
This is how a man reloads!
Version 1 and version 2 - double trouble.
Version 1 and version 2 - double trouble.
You don't wanna mess with this Master Chief.
You don't wanna mess with this Master Chief.

Materials List - For Halo weapon crafting

Here is a list of all the materials that can be purchased online via Amazon.

We Sell Mats Interlocking Anti-Fatigue EVA Foam Floor Mat, Light Gray
We Sell Mats Interlocking Anti-Fatigue EVA Foam Floor Mat, Light Gray

You only need 1 tile to make the shotgun, however, I am sure you can find uses for the rest. I like to stand on one while working, less stress on the bones.

 
Foamies 11.81 Inch x17.7 Inch 3mm Foam Sheet Feuille Mousse Black Noir
Foamies 11.81 Inch x17.7 Inch 3mm Foam Sheet Feuille Mousse Black Noir

A couple of these sheets will do for the detail work. Save the remainder for future projects

 
Rust-Oleum 7215830 Hammered Metal Finish Spray, Black, 12-Ounce
Rust-Oleum 7215830 Hammered Metal Finish Spray, Black, 12-Ounce

One can of the hammered black will give you a couple coats for your color base

 
303 Stainless Steel Round Rod, Unpolished (Mill) Finish, Annealed, ASTM A582, 1/4" Diameter, 72" Length
303 Stainless Steel Round Rod, Unpolished (Mill) Finish, Annealed, ASTM A582, 1/4" Diameter, 72" Length

You will need support rods to prevent flexing. A dremel or bolt cutters are needed for this material

 
Ledwholesalers 400 Nm Uv Ultra Violet Blacklight Flashlight 3 Aaa, 7301uv400
Ledwholesalers 400 Nm Uv Ultra Violet Blacklight Flashlight 3 Aaa, 7301uv400

This flashlight is the correct size and very bright. Be sure to cut off the strap

 

Seal the foam with heat - A veterans tip

Before I work with a piece of foam I seal it using the heatgun on high temperature. This has 2 nice advantages for the small amount of time invested.

1) When you cut heatsealed foam with a high temperature hotknife you get less shriviling and/or melting and are able to achieve crisp lines for a nicer finished product.

2) Heatsealed foam uses far less plasti dip paint to rubberize, saving you $$$ in the long run

The Heatgun - A powerful tool in your foam crafting arsenal

You can craft foam without a heatgun by scoring the back of the foam, glueing and re-scoring until you have your desired shape... or you can use a heatgun and pwn that foam in mere minutes. The heatgun also allows you to heatseal the smooth side of the foam making it easier to cut and shape later.

Black & Decker 9756 10-Amp Dual Temperature Heat Gun
Black & Decker 9756 10-Amp Dual Temperature Heat Gun

I've worked with power tools for over 20 years now and I prefer to buy quality and durability over cheap. For power tools I choose Black & Decker, Mastercraft, Dewalt or Makita when possible.

 
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Halo Shotgun Crafting Stage 2

If you are using our patterns you will need to tape the multi-page shapes together prior to cutting the foam. Use the thick blue dotted lines for a guide. Outside lines are black, cut out the basic shapes from the correct thickness of foam as indicated on the patterns. The overall length does not fit on a 24" foam mat, you will need to glue the edges marked "special" together after cutting the shapes. Don't worry about doing a nice glue job on the the seam, it gets covered later. That was easy.

In these tutorial videos I cover cutting 45 degree angles for the grip detail and burning details with the wood burning tips. I also show how to hollow out the sights for a diffuser panel and LED.

Hotknife cuts and burn details

Hollow sights for LED placement

#1 Tool for Foam Hobby Crafts

Walnut Hollow Creative Versa-Tool
Walnut Hollow Creative Versa-Tool

The multi purpose versa tool kit is by far the tool I use the most and I have tested a few. This is the exact item I use for foam crafting and not only is it durable, it gets very hot and comes with all the goodies you will need. With the hotknife attachment you can cut out shapes and make precision cuts. With the branding irons you can burn in details, rivet holes or even add battle damage. This kit even has a soldering tip and a small spool of solder for any custom LED work you do. Buy this tool for foam crafting satisfaction, I did.

 
versatip-crafting-tool
versatip-crafting-tool

Tools you will need - For your Halo weapon project

The main tools I use for foam crafting are the hot glue gun, the heatgun, the hotknife, the dremel and the wood-burning kit. Scalpels and xacto blades will work, however, a hotknife makes the work so much easier and with a much nicer finish. The dremel works great for sanding seams and to keep your hotknife sharp. The heatgun is optional, but again, using one will produce a nicer finish for your project. If you absolutely just can't tolerate working with hotglue and you just can't seem to find your way around that, then use crazy glue.

Surebonder DT-280F Dual Temperature 60 Watt Full Size Standard Glue Gun
Surebonder DT-280F Dual Temperature 60 Watt Full Size Standard Glue Gun

The little hobby crafting glue guns will work, however, if you plan on doing many projects get yourself a larger professional grade glue gun. Dual temp works great as you can use high temp for gluing the foam and low temp for smoothing over seams.

 
Black & Decker 9756 10-Amp Dual Temperature Heat Gun
Black & Decker 9756 10-Amp Dual Temperature Heat Gun

With a heatgun you can get a nice shape to your rounded areas, such as the front grip.

 
Dremel 1550 T2 Versa Tip Multipurpose Tool  Kit
Dremel 1550 T2 Versa Tip Multipurpose Tool Kit

This is the single most used tool for working with foam, it has the coveted hotknife attachment as well as the branding tips.

 
Dremel 300-1/24 300 Series Variable-Speed Rotary Tool Kit
Dremel 300-1/24 300 Series Variable-Speed Rotary Tool Kit

With a dremel you can hide seams, grind down angles and router out areas. Very handy.

 
Xacto X5175 Deluxe Woodcarving Set
Xacto X5175 Deluxe Woodcarving Set

No heat, no power, but still has some very useful blades for detailed or tricky areas.

 
OLFA 5003 L-1 18mm Ratchet-Lock Heavy-Duty Utility Knife
OLFA 5003 L-1 18mm Ratchet-Lock Heavy-Duty Utility Knife

This is my personal utility knife of choice. With the ratchet lock you can set your cutting depth for accurate mountain or valley cuts.

 
Aluminum Yardstick (36 inches long)
Aluminum Yardstick (36 inches long)

If you use a hotknife you will need a metal ruler.

 
The Classics Stainless Steel Ruler with Cork Backing (TPG-152), 12 Inches
The Classics Stainless Steel Ruler with Cork Backing (TPG-152), 12 Inches

The yardstick can be bulky for smaller cuts, try a 12-incher on for size.

 
Staples Talking EASY BUTTON - Complete With Batteries
Staples Talking EASY BUTTON - Complete With Batteries

Use this to make any project... well, easy. That was easy.

 
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Halo Shotgun Crafting Stage 3

Assemble and detail your weapon

Now that you have your patterns and basic shapes cut out you will need to assemble the shotgun. Start by glueing the main shaft and grip part to the barrel end on the edge marked "special". Then cut channels and add your metal rods and glue the 2 main sides together, this gives your basic outline. Shape your front grip in a U shape and attach using the guidelines on the pattern. Cut the grooves for the front grip wrap before you shape it with the heatgun, and then attach it to the front grip. Add the 3mm foam details to the butt, grip, stock and lower barrel and attach both barrels. Attach the trigger and finger guard. Add the 10mm detail to the end of the butt. Lastly wrap the cardboard tube in the 3mm detail, attach the sights and glue it to the top of the barrel. That was easy.

Sandwich metal rods between the 2 main parts

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Cut trenches for the rods at a depth of their radius in both layers. Glue the rods securely in one layer and allow to set, then glue the second trench and compress the two together. Make sure all the edges line up nice then place a large board on top and let the glue set before glueing the edges.

Top Front Barrel Wrap

To stabalize the top barrel there is a shape on page4 marked "top front barrel wrap" cut from 3mm foamie. Wrap it around the barrel and glue it to the center and end of the top area. After you add the top barrel you can finish the front detail by adding the small half-oval shapes from 10mm foamie found on page8. Cut 2 and use 1 for each side, you can even carve them down a little with your hotknife to make them appear more rounded, and thus more game accurate.

Attach the foam detail to the cardboard tube

Finished Shotgun Reference Pictures - After Hammered Black primer applied

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Halo Shotgun Crafting Stage 4 - Seal and paint your shotgun

shotgun
shotgun

To finalize your masterpiece you will apply a latex or rubber sealer first, we recommend Plasti-dip for best results and Krylon latex spray-paint as an alternative. We spray 2 light coats for maximum seal with minimum drip and then let it fully dry for 24 hours. Next step is to prime your shotgun with a base coat of black. We used hammered black metal for our shotguns, 2 light coats. Once primed and dry you are ready to add your own custom details. We painted the butt and both grips flat black, along with the small ovals along the top of the gun and any 3mm "cliff" edges. We used hammered copper in a few areas along with some subtle dry-brushing. The sharp edges received metallic silver trim and silver dry-brushing was applied to high wear zones. Lastly a little bit of red for contrast. Very nice, kudos to Longshot for the fantastic paint job. That was easy.

Painting Supplies - Some goodies you may need

Foam Shotgun Version 2 Indoor Photoshoot - Featuring Spartan Intimidator, pictures by Longshot-x

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Halo Weapons on Amazon

Are you taking the shotgun challenge? Have a question about the patterns? Feel free to ask here.

Ask the armorer

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    • profile image

      anonymous 3 months ago

      Do you cut out two main parts and glue them together after you put the supporting rods in or just one main part

    • profile image

      Sasq23 3 years ago

      I am interested in purchasing the patterns. How much are they and how does the transaction work?

    • profile image

      zac123attack 4 years ago

      ive tried to make the halo shotgun and its not working out to well

    • profile image

      zac123attack 4 years ago

      ive tried to make the halo shotgun and its not working out to well

    • profile image

      zac123attack 4 years ago

      hey I have been searching the web for a day or two and I cant find any halo costumes for sale that are good, so I have been looking in google images today and I saw ur costume and I wanted to see. I thought it was made out of metal until I heard u used foam, and I was wondering if u can make me a halo armor please cause that stuff u make is awesome, and I will pay u for the armor.... and is the helmet made out of foam to?????? when or if u reply let me know.

    • profile image

      anonymous 4 years ago

      can you make gravity hammer

    • profile image

      anonymous 4 years ago

      is it hard

    • profile image

      anonymous 4 years ago

      Where do I get the patterns from?

    • profile image

      anonymous 5 years ago

      can you make a magnum pistol

    • profile image

      frank-gumpert 5 years ago

      @LongShot-X: In case anyone else wants to know the piping is 1/2'' pvc for the upper smaller barrel and 3/4" for the larger under shell tube.

    • profile image

      frank-gumpert 5 years ago

      @LongShot-X: I received them. Thank you. Quick question what are the red and grey tubes you use for the barrels? I don't see them in the materials list. How long? What size? I began cutting and noticed that they were missing. Thank you agin.

    • LongShot-X profile image
      Author

      LongShot-X 5 years ago

      @frank-gumpert: My appologies Frank. They have now been emailed to you. Please let me know if you got them successfully.

      Thankyou for the purchase and I hope to see how it turns out.

    • profile image

      frank-gumpert 5 years ago

      I bought the shotgun plans 3 days ago and have not yet received them. Please send them asap.

      Frank.gumpert@yahoo.com

    • LongShot-X profile image
      Author

      LongShot-X 5 years ago

      @anonymous: You have to create it (We used a coat hanger wire) It is the bar that is just under the trigger (trigger guard).

    • LongShot-X profile image
      Author

      LongShot-X 5 years ago

      @anonymous: "Triple grey lines" are the pencil drawn lines. "Triple grey line - 5mm V shape cut lines for barrel grip"

      Raise in the patterns, means that your going to cut out that shape in the indicated thickness and glue it to the shotgun at that spot.

    • profile image

      anonymous 5 years ago

      on the first sheet of the plans I ordered there is a small in pencil notation that says angle trigger guard and then has a shape drawn that looks like a malformed U what am I supposed to do with this piece of the patterns? is that simply a notation for other parts of the sheet or is this a piece that I am supposed to cut out and create?

    • profile image

      anonymous 5 years ago

      when you say raise in your patterns what exactly do you mean by this? another question when you say triple grey line do you mean the pencil drawn line?

    • profile image

      anonymous 5 years ago

      man's best friend!

    • davidangel profile image

      davidangel 5 years ago

      @anonymous: This is a weekend project, it should only take a couple of days with the patterns, plus a day to paint it.

    • profile image

      anonymous 5 years ago

      how much time should I have to take out of my schedule to make this?

    • davidangel profile image

      davidangel 5 years ago

      @anonymous: Depends on where you shop and if you need the tools or not. If you shop online you can tally up everything listed on this page for a good estimate. The mats are typically sold minimum 4 in the 2' x 2' variety. A set of 4 will cost $16+ in the big box stores, I watch for sales. Dollar stores and thrift stores are great places to get some of the materials cheap.

    • profile image

      anonymous 5 years ago

      How much is the average cost to make a shotgun? With supplies and everything.

    • profile image

      anonymous 6 years ago

      Way cool, now if I need to make Halo weapons I'll know where to come for just the best instructions!

    • profile image

      anonymous 6 years ago

      dude how do u live wit yourself this is too koo

    • LongShot-X profile image
      Author

      LongShot-X 6 years ago

      Awesome lens on the halo shotgun prop