Halo 3 Legendary wearable helmet conversion

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Combaticron

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I built a foam Master Chief for my son, and to save time I bought the cheap Rubies helmet. It made him look like a bobblehead. (It was OK for a one-time deal.)

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With 405th Pacific Spartans at Comikaze 2013

I'm not yet up to building a foam helmet, so I decided to modify a Halo 3 helmet/case. This thread inspired me to do it, and showed me how to take it apart: http://highimpacthalo.org/forum/showthread.php?t=35940

I'm usually in a hurry (in this case, I only had a couple of days before Long Beach Comic Con) so I don't take a lot of pictures during the build. Still, here are a few.

I took the case apart per the tutorial and then sprayed (some of) the exterior with silver, then black, then olive drab so that I would get a nice weathering effect when I scuffed the edges. I didn't do this uniformly for some reason, so in some places I scuffed it down to the original green paint or the plastic.

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I started putting it back together using 5-minute epoxy, but toward the end I just used copious amounts of hot glue. (That turned out to be not the best plan.) I melted some of the pins down for security, and ground down anything sticking out. The black piece at the back of the neck had to be cut down for my son's head to fit.

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I used two types of LED lights from the 99-cent store. I pulled the LED (plus wiring and resistor) from four of these USB lights, as well as the clear plastic lens, which I fit into the helmet after drilling out the light domes. I used the battery pack and switch from a clip-on desk light.

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The hardest part was fitting the motorcycle helmet visor, which required cutting and gluing. The bend puts a lot of outward pressure on the helmet, and the chin pieces came apart at the seams after a couple of days.

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Foam is a must! A fan would be nice.

And here it is completed, with judicious scuffing and dry-brushing. The fit and finish aren't perfect (there are big gaps between the visor and the helmet) but I'm pleased. I have some repairs to do (chin piece), and I would like to secure the visor with screws and add a fan. My son's head is about 21" so it's perfect for him (but definitely not for an adult-sized head).

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I have another Legendary that I might also convert, using the lessons I've learned on this one. Time will tell.

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Full gallery here: http://smg.photobucket.com/user/Max_Deployment/library/Halo?sort=2&page=1
 

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That's a great-looking helmet. I took my Legendary Edition helmet with me on a deployment, started to detail it up, then decided to make it wearable. It took some work, but the LE helmet can be wearable by an adult (size 7 1/2 melon). In the end, the visor took longer to get right than the helmet. The LE helmet is a great, fast and inexpensive way to a nice Mk VI helmet. I'm still surprised more builders didn't take this route.

Redshirt
 
Not with my big ol' grape.

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Ha! That is a great pic! The look says it all. Still a great-looking conversion.

Happy Thanksgiving.

Redshirt
 

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Well, the jaw finally gave up the ghost. The chin is three pieces and the visor forced them all apart. I took the whole jaw off and I'll be epoxying it all back together. Lesson learned.
 
Since I had the jaw off, I thought I'd make some improvements. My son complained about the visor fogging, so time for a fan. Carpathia's build video inspired me.

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A little sloppy with the cutting wheel there.

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I bought a couple of 3-AAA switched battery packs and I'll attach them inside with magnets.
 

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