Halo 4 Helmet - Full Size , Adult

Original project uploaded by Big_red_frog on thingiverse in 2013, see hackaday project for more details including assembly.

I modified this project which remixed the original, https://makerworld.com/en/models/188118?from=search#profileId-207294

I included the original models, but wanted the modifications like the battery tray, M4 bolts, and the tie wrap options.
I printed the tension pins in PETG, scaled to 104% to account for shrinkage. They were less brittle when fitting parts together. PLA pins snapped easily along the layer lines.
I dry-fit assembled first to ensure the tension pins were installed correctly, and then reassembled with super glue at the entire seam, for every single section.
Filament I used was Bambu Lab Matte Dark Green, generic clear PLA, and Greeetech Silk Gold which all came out looking fantastic.

All models in green are the modified parts. All models in black are their original counterparts.

Hardware list per original design:
3/8" x 1/10" magnets, 19 pcs
3/8" steel cups, 15 pcs
Jowl insert retaining magnets are 1/4" x 1/10", 4 pcs
Tension pins throughout model are 1/8" x 3/4", 57 pcs
5mm LED's in all inserts