1st Build The Red ODST Halo: Reach build log.

KGSupreme

New Member
Intro:
Hello everyone. I figured now was about time that I stopped lurking and started posting my own build log, I'll try to organize it for fast browsing. I have wanted to build my own armor set based off my custom armor from Halo: Reach, it's been nearly a full decade since that game came out and I have finally got around to building it. I purchased a 3d printer last year, a Creality CR-10s, and after a few prints trying to get used to the dynamics of 3d printing and 3d modeling I think I finally reached a point where I am comfortable with printing a full armor set.

I plan for this thread to just be a collection of my progress and some extra information to lead other people in the right direction or give inspiration. I don't really think anyone should use this as a tutorial, nor do I plan to write out very direct instructions on how everything is done. Still, thanks for checking it out. It's also a two way street, if you have any words of encouragement or information to share that may be relevant, I would appreciate it. Thanks

Shout-outs and experience:
First, a reference to some of my previous, non-Halo related projects. Linky . (Bonus Shadowhawk)
As you can see if you browse my photos, a lot of my previous projects were either made with wood or metal, and some 3d printed parts I purchased from someone else. Now that I have my own printer, I have been trying to practice more with 3d printed plastic parts from the ground up. This involves learning about the programs involved, specifications of infill, materials that can be used, hardware upkeep and maintenance, intricacies of a 3 day print job that may run out of filament on day 2.... etc. lots of stuff to learn.

Second, a big shout out to MoeSizzlac, MDBDesigns, @KitKatGoose, @TD0013, electricknite, and TurboCharizard for any 3d models, images, or miscellaneous resources and inspiration for this build, couldn't have done any of this without y'all leading the way. Hell, the whole 405th community does so much to provide helpful tips and great inspiration to try and get this done, you all deserve credit and kudos. Thanks.

References:
Anyways, here is the armor set I want to build as a reference. One image from Vanity, and the other is an action figure from the Mcfarlene series of toys that I put together and painted wayyyyy back in the day.
VanityArmorLoader.png TgaPJ.jpg

You can see it's a red ODST set based on the armor from Halo: Reach. I don't have the xbox 360 set up anymore, so going on there to make the armor for picture references isn't going to happen. And while I do have Reach on the PC Master Chief Collection, I have not spent time trying to acquire all the gear on there for reference. So looking around online will just have to do for now.

Things I have purchased to make it easier:
Gloves

I bought some protective gloves off Amazon for cheap, they look good enough for what I will use them for and I don't mind sacrificing them for the armor build.
Gloves.png

Grenades
Thats a whole nother issue. I considered 3d printing each grenade separately, but I wanted to save myself the time and material by using some Airsoft GL grenades I already owned from playing airsoft. I had to purchase 2 more to complete the set for the belt and chest piece, but the two extra I received are no the same color..... I'll probably just use those two on the chest piece and just say they are "Elite Buster" grenades or something. Idk. They look a whole lot better than I could make, and hopefully it's easy to show a convention that they are not real munitions nor will they be able to fire anything. When you load bb's into them you have to put a rubber plug in the hole to keep them in place, if I don't load them they wont be able to fire anything. Anyone have experience with something like this at a convention?

Undersuit
I purchased a full body lycra suit off Amazon, I plan to make some undersuit accents as part of the full armor set, but I have not gotten around to that yet.


Please bear with me while I edit and add to this thread.

Saving other posts in the thread for progress.
 
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KGSupreme

New Member
Saving this post for progress pics and stuff.

3d model sizing
3d model full sizing.png

As you can see, I had to assemble all of the 3d models I downloaded and a male body model to try and mock-up all the objects to see if I could size them properly. I am glad I did so far, because the default sizes for the models would not have fit my head, legs, feet, hands, waist, chest, or arms. I am a fairly big person, 6' 3" 250 lbs last I checked, and I will need to lose some weight(Damn you quarantine! Spring 2020 never forget) to make this all look better on the outside.

Progress Pictures.

BOOTS

I started with the boots first.
At the moment I think I'm just going to use some of the boots I have on hand, a pair that I purchased from Academy sports a few years ago for like $30 US. So far the models I have printed fit really well around the boots, and the laces underneath shouldnt be an issue. I could just buy some material to cover that up if I really feel the need.
bootmockup.jpg bootarmormockup.jpg

While printing the front section of the right boot, I had to swap filament near the end of the print. Even though it missed a line and nearly messed up entirely, I was lucky that it was an easy fix.
bootarmorfilamentswap.jpg bootarmorprintmessupsotra.jpg

I have not figured out how I am going to get everything attached to the boots. I may have to sacrifice the boots for the good of the armor, and glue everything together in some fashion. Maybe some metal clips and screws would be good to keep the smaller parts attached to the lower parts, but I have not come up with a solid idea yet.

HANDS
The hand plates were easy enough, measure the back of my hand and make the 3d model similar in size.
glovemockup.jpg
I think I will use the hand armor as a practice platform to get the paint job and detailing that I want for the rest of the armor, it's easy to replace if I mess it up too much. Glueing the armor to the gloves is the most straightforward way to get these put together.

LEGS AND KNEES
I printed the knee pads before the rest of the legs. The best way to print them for the least amount of material was at a slight angle on the build plate for the printer, and it turned out so perfectly that when the heated plate had cooled down after finishing the print, I found the completed piece had fell over. The heat from the build plate made it so the PLA plastic stuck to the plate the whole time. So awesome.
Kneepadprint orientation.jpg TwoKneepadsdone.jpg

I was looking at how I should go about printing the lower leg/shin pieces. Do I segment them into smaller pieces to reduce the liklihood of messing up a long print job, or print the whole thing in one go to make it all uniform and reduce the work I need to do later to clean up any creases or splits.... HMMMM
lowerlegarmormaterialcost.png
Also you can see that it will take nearly 500 grams of material to print ONE lower leg armor piece. This means nearly half of an entire 1 kg spool of material for one piece of armor. At the moment we are in May 2020 of the pandemic/quarantine, so Amazon has a low stock of the PLA material I like. Might need to think this one over.

BELT AND BUTT
The belt and butt plate for the armor will take a lot more material than I thought it would at first.

The butt plate was easy to size, I will likely have to put together a nylon belt and some clips to get everything to stay together. Also, this one was printed vertically and the whole support structure came out in one easy pull rather than having to scrape off all the remaining burrs. Perfect.
Buttplateandsupportremove.jpg

I have not printed the belt/codpiece.

CHEST
I couldn't find the right type of chest piece I was looking for, the HP/HALO chest piece. Unluckily it's a very vague name for a specific chest piece. LUCKILY MoeSizzlac is awesome and was able to put the chest piece together really quickly. Link to his Download
LowerChest Piece.png
I have not printed this yet.


SHOULDERS
I have not printed this yet.


ARMS
I have not printed this yet.


HELMET
I have not printed this yet.

GUNS
I have not decided what guns I want to print yet. Probably going with the Grenade launcher because the armor has the grenades as an accessory, I might do the Halo Magnum just because it won't be too big. I want to do either the DMR from Reach or the Battle Rifle. Not sure yet. I likely won't do anything huge like the Spartan Laser or a machine gun turret.
 
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Best of luck with your build! With the airsoft grenades, I think you gotta be really careful. Not only does the 405th have some problems with people making airsoft guns/armour (though since yours is for display only it might be alright), conventions may have an issue as well, even if they don't work. What is it made of? I think my local conventions would have problems with metal airsoft grenades.
Also with your shins, do you need to add support on it? There's a few spots that look like they may struggle without it.
 

KGSupreme

New Member
What is it made of? I think my local conventions would have problems with metal airsoft grenades.
Also with your shins, do you need to add support on it? There's a few spots that look like they may struggle without it.
The grenades are aluminum, fairly heavy and very obviously made of some metal. I don't plan on making any of the weapons functional, even the grenade launcher I want to make won't be able to open the breach, and the tube doesnt fit the grenades according to the 3d model I downloaded already. Might be a good Idea to paint the insides of barrel for any weapons I make bright orange. I'll have to check ahead with any conventions I plan on going to, maybe printing the grenades might be the way to go.

The shin armor might need some support, I tested the overhang for my printer and the PLA I use and it goes up to 65 degree without failing, I tend to make my prints have support for anything about 55 or 60 degrees just in case depending on the complexity.
 

KGSupreme

New Member
Are you reinforcing your prints with anything?
My first thought was using some of that XTC-3D epoxy product that is primarily used to smooth 3d prints, since it is an epoxy it dries really hard and adds a protective layer to the PLA plastic I am using. The main issue there would be how much that stuff costs compared to how much surface area we are talking about for a full armor build. I have not come to a conclusion on what to use to attach the armor pieces to the undersuit, do I use snaps, buttons, clips, straps or some other thing? I get the feeling it's going to be a little bit of everything depending on the armor piece and it's location.

The way that each armor piece was designed there are plenty of empty cavities on the interior facing the body, I could fill those empty spaces with some sort of epoxy or foam filling material. And I was able to print the pieces I have so far with more than 80% infill so they are significantly more dense than my average prints, that should help make them sturdy. If paint+primer+clear coat is enough to protect the PLA material from degrading then I should be good to go.
 

TurboCharizard

Division PR, RMO and BCO
Division Staff
405th Regiment Officer
Community Staff
My first thought was using some of that XTC-3D epoxy product that is primarily used to smooth 3d prints, since it is an epoxy it dries really hard and adds a protective layer to the PLA plastic I am using. The main issue there would be how much that stuff costs compared to how much surface area we are talking about for a full armor build. I have not come to a conclusion on what to use to attach the armor pieces to the undersuit, do I use snaps, buttons, clips, straps or some other thing? I get the feeling it's going to be a little bit of everything depending on the armor piece and it's location.
XTC-3D can go quite a long way if you're careful. I coated two suits using one 24oz kit (they float around $30-$40 which isn't terrible).
 
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