Halo Reach build - First Build

Vossie

New Member
Still only on the helmet as of posting this but honestly should have made this thread a long time ago and if I did maybe I would've been more consistent in my progress. I started this build in April of 2025 and procrastinated for months, It's been sat on top of my printer the whole time gathering dust, but I've regained my motivation and I will see this thing complete.

1770836129189.png
1770836196654.png

Here's my spartan I used MCC to design which is what my finished armour will (hopefully) eventually look like.

1770833377338.png

So obviously this is early stages, I only had 2 parts printed and held them together by frog tape just to see how It'd look with the visor, which I bought off of etsy for more than I probably should've spent but I didn't, and still don't, have access to a vacuum former so it was my only option at the time.

What I didn't realise until later was the visor didn't actually fit because the buck used to make it was a slightly different model to what mine is. In hindsight this should've been obvious and I definitely should've have invested in making/buying a vacuum former but I was too eager to get it done, which is funny considering it's taken me several months to pick this back up again.
1770834292179.png

A this point I had all the parts printed ready to fill and sand once I had glued the pieces together. I chose to get a soldering iron and go along the seams on the inside melting the pieces together rather than using a glue and glue activator. A method I didn't know existed until a few months back but oh well too late now. I do wish I could've done it this way instead because I melted the seams a tiny bit haphazardly and cause it to be slightly misaligned but it doesn't affect the print that seriously. I also used said soldering iron to cut away at the visor trim so the visor could actually fit but actually made it look kinda wonky and so I spent a sh*t ton of time trying to sand that to make it somewhat nice to look at. It's not perfect but I don't think it's very noticeable unless I point it out.

1770834697366.png

Because I didn't originally plan on making any kind of thread detailing my journey, there's no picture of how it was between this image and the last, but luckily nothing eventful happened in-between. This point in the image above is roughly when I picked this project back up and went back to do some more sanding in areas I might've missed before and re-prime it for paint.

To fill in all the print lines I used something called "modeling paste" which isn't typically used for this sort of stuff but I saw a guy on YouTube use it and he said it was good so I said f*ck it and bought it. However something I knew about this stuff and didn't realise it was be a pain the arse later on, is 2 things, A) it's water soluble meaning no wet sanding and B)I slathered this stuff on with and old paint brush and it got into every little crevice and because I don't have any sanding pens for small corners, it made the print look awful. So then I had to painstakingly sand what I could with regular sheets of sand paper. Again, you'll only notice it if you go looking for it.

1770835730257.png

Another jump cut here to recently when I painted the dark/light greys and did the orange accents today. The in game model doesn't actually make anything on the JFO helmet orange when you select it as a secondary colour. The stripes were originally red so I changed them to orange so that it'll match my other armour pieces when I make them. (The orange looks much more neon in the photos than in person).

1770837337629.png
1770837584991.png

And here is the most recent progress, I added the upper stripe I forgot to do before (which is white in game but I wanted more orange on the helmet) and painted the neckline black, I haven't done the neckline on the front of the helmet because I ran out of daylight. Probably won't be able to do that for a few days, as I'm working. So yeah that's my progress so far and I'll be posting updates to this thread as I go along. My only enemy right now is the bad weather here in wales and my own procrastination (which I'm managing to fight off!).
 
Helmet felt off to me so I retaped it again and painted more matte black on it, will post a picture when it's dry after I get back from work.

Edit: I was right, it looks much better with the extra black.
1770916433850.png
1770916378379.png
 
Last edited:
Now while I let the matte black fully cure overnight, I've added 3 magnets to each side of the neckline trim (the holes were drilled way before I started painting because the file doesn't actually have any holes for magnets) so I can detach the neck piece and actually get it on my head. They're taped down so they don't magnetise to their neighbour magnets and stay actually in place while the glue cures.
1770920201387.png
1770920366556.png
 
Looks good, i also vacuum formed that visor for Energibill and i thought it was weird that it was on outside instead of inside of the helmet
Thanks! I'm not sure if it was originally meant to sit on the outside but I've altered the print so the visor does fit from inside now
 
Still only on the helmet as of posting this but honestly should have made this thread a long time ago and if I did maybe I would've been more consistent in my progress. I started this build in April of 2025 and procrastinated for months, It's been sat on top of my printer the whole time gathering dust, but I've regained my motivation and I will see this thing complete.

View attachment 373123View attachment 373124
Here's my spartan I used MCC to design which is what my finished armour will (hopefully) eventually look like.

View attachment 373114
So obviously this is early stages, I only had 2 parts printed and held them together by frog tape just to see how It'd look with the visor, which I bought off of etsy for more than I probably should've spent but I didn't, and still don't, have access to a vacuum former so it was my only option at the time.

What I didn't realise until later was the visor didn't actually fit because the buck used to make it was a slightly different model to what mine is. In hindsight this should've been obvious and I definitely should've have invested in making/buying a vacuum former but I was too eager to get it done, which is funny considering it's taken me several months to pick this back up again.
View attachment 373116
A this point I had all the parts printed ready to fill and sand once I had glued the pieces together. I chose to get a soldering iron and go along the seams on the inside melting the pieces together rather than using a glue and glue activator. A method I didn't know existed until a few months back but oh well too late now. I do wish I could've done it this way instead because I melted the seams a tiny bit haphazardly and cause it to be slightly misaligned but it doesn't affect the print that seriously. I also used said soldering iron to cut away at the visor trim so the visor could actually fit but actually made it look kinda wonky and so I spent a sh*t ton of time trying to sand that to make it somewhat nice to look at. It's not perfect but I don't think it's very noticeable unless I point it out.

View attachment 373117
Because I didn't originally plan on making any kind of thread detailing my journey, there's no picture of how it was between this image and the last, but luckily nothing eventful happened in-between. This point in the image above is roughly when I picked this project back up and went back to do some more sanding in areas I might've missed before and re-prime it for paint.

To fill in all the print lines I used something called "modeling paste" which isn't typically used for this sort of stuff but I saw a guy on YouTube use it and he said it was good so I said f*ck it and bought it. However something I knew about this stuff and didn't realise it was be a pain the arse later on, is 2 things, A) it's water soluble meaning no wet sanding and B)I slathered this stuff on with and old paint brush and it got into every little crevice and because I don't have any sanding pens for small corners, it made the print look awful. So then I had to painstakingly sand what I could with regular sheets of sand paper. Again, you'll only notice it if you go looking for it.

View attachment 373121
Another jump cut here to recently when I painted the dark/light greys and did the orange accents today. The in game model doesn't actually make anything on the JFO helmet orange when you select it as a secondary colour. The stripes were originally red so I changed them to orange so that it'll match my other armour pieces when I make them. (The orange looks much more neon in the photos than in person).

View attachment 373128View attachment 373129
And here is the most recent progress, I added the upper stripe I forgot to do before (which is white in game but I wanted more orange on the helmet) and painted the neckline black, I haven't done the neckline on the front of the helmet because I ran out of daylight. Probably won't be able to do that for a few days, as I'm working. So yeah that's my progress so far and I'll be posting updates to this thread as I go along. My only enemy right now is the bad weather here in wales and my own procrastination (which I'm managing to fight off!).
Good job on your JFO! Looks great! Also have a JFO of my own! Im yet so close done with mine!
 
Good job on your JFO! Looks great! Also have a JFO of my own! Im yet so close done with mine!
Thanks! I actually came across your JFO thread the other day It's looking great dude! I did actually post a reply on that thread asking what you did to attach the neckline because I was having an issue with it but I ended up sorting that out myself. (The fix was more magnets )
 
1771107328395.png

The glue has dried so now the neck piece snaps on just fine and holds fairly well. As I mentioned somewhere above, because I melted the helmet halves ever so slightly out of alignment the neckline does a more pronounced gap between it and the whole helmet and I've triple checked that it's flush on every side. This doesn't really matter to me tho tbh because no one is going to be looking at the back underside of my helmet. Plus it doesn't look as bad in person.

Now all that's left for the helmet is the visor (which I'll sort out later this month after payday), padding the inside with something like upholstery foam, magnetically attaching the forehead accessory, which I'll have to buy some stronger magnets for and finally weathering and clear coating. But in the mean time I'll likely be printing out the waist pieces/hand plate to stick on my gloves. :lol:
 
1771263552045.png

I'm back with another update! I'm printing off the back pieces for the hands, above in the image is me test fitting my first piece onto my gloves. It felt a bit small to me so I'm printing 2 more 10% larger than the 1st. The gloves I'm using are old paintball gloves that I bought in a charity shop, there was a rubber backplate that was sewn on where the printed piece will be going and because it wouldn't have stuck to the rubber I cut it off.

Update : 10% larger was definitely the way to go, I think it looks way better!
1771283189412.png
 
Last edited:
Got my next update for you guys! I will probably start posting less updates rather than my previous 1 update every time I do a minor thing. I'll probably make my next post when I actually make more significant progress after this one, so here's what I've done since last time!

1771451592104.png

I went to a local re-upholstery shop to buy some upholstery foam and after chatting with the guy there for a bit he gave me a few good sized squares of his scrap foam for free! This is why you support local businesses!! Anyway, I cut the foam to size so my head fit nice and snug in the helmet. I attached them using velcro strips for future proofing, so if in the future they get all gross after absorbing my sweat, when I eventually wear this to a con, I can cut new pieces to swap out whenever I want! Plus if I want to make any sort of additions inside the helmet later down the line, like a fan or voice modulator, I can easily take out the foam/velcro.

1771451998302.png
1771452025067.png


While I was printing out the back of the boot today, I sprayed filler primer on the hand pieces which I would've sanded down today but it started raining not long after my second coat so that gotten set aside for another day.

1771452198235.png
1771452214355.png


After I realised I won't be sanding or spraying anything today I decided to put my next print on, the boot cover. (I've called it the boot cover cuz idk what it's actually called) The first attempt went perfectly with no issues printing but what I didn't realise until after the print was done is I forgot to scale it up so then of course I had to chuck the old one and print a new cover. Which is the one in the image above. So that makes 2/3 for boot 1! I'm probably gonna try to print the second boot cover before heading into work tomorrow morning, I would try and print a bigger piece while I'm there but I have trust issues with my printer and I refuse to print any big pieces while I'm not in the house.
 
looking hecka good there making some real progress. keep up the good work.
Thank you! I'm getting there, slowly but surely. Got some magnets that'll get delivered soon which I'm going to use on the head piece so it'll snap on and off as I wish. I've debated with myself on many methods of how to colour my visor and I've decided on the good old reliable idye poly that many people seem to use. I also managed to get my hands on some Spaz Stix mirror chrome so I can actually make my visor reflective but still keep the visibility. And while I wait for all of that to get delivered I'm gonna be printing more pieces in the meantime. I would have the front half of the first boot done printing by now but I forgot to scale it up by 10% and only remembered halfway through. :cry:
 
We have all been there with forgetting to scale our prints.

i have now officially used both spaz stix rattle and and airbrush for chroma and their stuff is good. i look forward to see your next prints come out.
 
Edit: Ignore everything I say in this post about my printer not working. Look at the following post.

I finally bring another update! But it isn't as cheerful as I wanted it to be. Disaster has struck, my printer as of writing this, is broken. I'm gonna try fixing it right after posting this but yeah it's not working. Initially I had a print fail because I ran out of filament, no matter a simple problem with an easy fix, how wrong I was. When I tried unloading the printer of the old filament for the new, it got stuck constantly trying to unload and never allowing me to put the new filament in. I think it was because the printer was sat for about 2 hrs without filament, which I couldn't swap out any sooner because I was in work when it happened. So I think some filament got stuck somewhere and in trying to get it out I short circuited the nozzle temperature sensor by accident. I have a bambu labs P1S for the record.

But it's not all bad news, might as well show off what little progress I've made this last week.

1772140678684.png
1772140873123.png

So since last time I finished printing out the boot pieces, nothing else has been done to them sanding wise as of yet due to bad weather (god I can't wait for spring). But at least I've got them printed out.


I glued in the magnets I ordered to the inside of the helmet and the head plate so I can now snap it on and off as much as I want. While the pull isn't weak it's not as strong as I was hoping so it can still be knocked off, I'm just gonna make sure I'm careful when wearing it.

1772140643457.png

After that I weathered the helmet using a tiny random pot of silver paint I had lying around and did a light black wash all over the helmet too. I might have gone a little light with the black wash so if I change my mind I can always go over it again with another but for now it's good. I am also not too far away from finishing the visor. I bit the bullet and paid way too much on some Spaz Stix mirror chrome and I've got the fabric dye to dye the visor too, however I still need a stockpot to do it all in, yet to find any second hand near me so far and I really don't want to buy a brand new one just to ruin it.

1772140932895.png
1772140976883.png

After doing the helmet weathering I also did the weathering on the gloves. Left image is pre-weathered and right is post and just before I glued the hand plates on.

1772141092076.png

And for the big finale of this update, the forearm..... I decided to buy a new armour model after finding Title wave designs MK V B model over on Cults 3d, my previous armour model was not optimised for 3d printing at all and I could get away with it for the smaller pieces so far but the only ones left now are the big boys and I rather not waste time and filament on failed prints. Plus this new one has been incredibly well designed for wearing (not sponsored btw), there's cavities for electronics, magnet slots so you can easily put it on and take it off and even a belt line built in to the waist so you thread any old belt you have into each piece. Anyway it's an upgrade for sure, I printed off 1st half of the forearm just fine then came the 2nd.......

I decided to trust my printer for once and print while I was at work and as I wrote at the beginning what a mistake that was. It got to 94% done before failing from no filament which was really frustrating. And now we're at the present, where I've got a broken printer which has really hit hard in the motivation department. Don't fret tho, I'm not giving up that easy. I'm gonna fix this baby up and get back on the grind soon enough. Peace for now tho. :cool:
 
Last edited:
Never mind guys I was just being dramatic. After sitting down to eat and calm down, turns out I'd knocked the nozzle temp sensor slightly loose and it's working like brand new again. I'm so done. Literally been freaking out for the last 4 hours over nothing. :confused:
 
Ok so new rolls of filament arrived today so more armour pieces will be coming in the next couple weeks! Finally got a sunny day today, so I was able to fill and sand one of the boots, unfortunately had some other things to do too so I only managed to do one boot and also ran out of primer so I'll have to pick some more of that up soon. My Spaz stix mirror chrome spray, that I definitely didn't pay an absurd amount for, arrived today too. Still can't do the visor, haven't found a pot that I can use for the dye yet and as I said in my post before I'm not buying a brand new one to ruin. Suppose I could check facebook marketplace/ebay? Maybe It'll feel less like trying to find a needle in a haystack.
 

Your message may be considered spam for the following reasons:

If you wish to reply despite these issues, check the box below before replying.
Be aware that malicious compliance may result in more severe penalties.
Back
Top