Halo Reach Jorge build part 2

I created 3D renders of Jorge's armor based on screenshot and a McFarlane figurine which I then used to make templates for cutting EVA foam on my new scroll saw.

Model:


Various stages of assembly:






The gray is 1/2 inch EVA foam and the orange is 3mm EVA foam used for raised details and creating the proper thickness of pieces. The entire thing is assembled using hot glue, which just so happens to be EVA based, making for an incredibly strong bond between the pieces.

The saw is working out wonderfully although I need to plan my template layouts better to minimize scrap pieces:


I need to finish my 3D model of Jorge's chest armor before I close off the rear of his pack so that it will interlock with the chest.