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*almost* finished Master Chief helmet.
This was a difficult one.
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It was supposed to be one single print. The first 3 attempts failed, but the 4th... I powered through. Where the blue tape is, the extruder on the printer hit the print and shifted 2mm... so I had to break the helmet to reglue it to fit. Then the bill/nose shifted so much that I had to cancel the print. since up to that point was about 4 days, I figured I would just eyeball in Netfabb where the print failed and retro fit the two pieces on to the existing print. It worked good enough.
This pic was taken on June 16th when I finally had it all together and the glue had dried.
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you can still see a lot of the flaws here. I like using black paint as a type of filler.. I can see the flaws and print shift, and its cheap.Works good enough.
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And here is my dual visor experiment that worked better than anticipated. The outer layer is a $5 'Replacement Face Shield, 8"x 15.5"x .040, Clear Polycarb, Model 15151' (amazon it!). It's very flexible, and can be cut with tin snips or heavy duty kitchen scissors (not recommended, but if thats all u have).
The gold under layer is a Visor material from our very own StonyPropsJim or IconProps (not sure his username here) (
Etsy Link here). So in Total, the visor cost around $30, and for most of it I simply used scissors to cut it. I used a dremel to cut the inner detail pieces with a diamond cutter blade, and then a file & 80 grit sandpaper along the edges to sand and make the edges smooth (careful, dont scratch your clear visor!). Installation is simply just pressure fit in place, and some hot glue in particular points to reinforce.
The vision is excellent, its like putting on a pair of sunglasses.
It's not perfect, but I'm super happy with it and I finished it without feeling too rushed for Halo Outpost Orlando here in a few weeks. I just have to install the fans, lights and padding.