Halo 4 Helmet Full Size ( Adult – 6’6″ plus )

Author: big_red_frog, published on 2013-09-01

Click this button to get the 3D model


This model is now DEPRECATED by the right size version at


The following should all be considered historical.

WARNING: I have a Goldilocks situation. Original model was too small, this one is too big, not horrendous and maybe the right size for master chief, but bigger than I was expecting.!

THIS IS TOO BIG, you have been warned.

This instance of the model is now complete, don’t build it unless you are well over 7ft tall.

I have added visor STL models that are only proof of concept for the the eventual vac form visor, but I will only do that step on the next proper sized version, they don’t have all mounting points, but enough to show the model is “true”.

Will be re-sizing again, rescale, remodel will be minimal as only requires pin and magnet placement rework and checking that the walls don’t become too thin.

All parts are being heavily thinned as well as up-sized compared to child sized version.

All parts have printed proof, please observe orientation closely to ensure minimal support implications.

For Rear Left Bottom corner pieces, despite triple checking pin alignments did not clash, in the one corner the vertical and horizontal pin do! so use 5/8 tension pins instead of 3/4 tension pins in the corner to avoid the clash.

Note in Jowl and chin pieces

Cavity for the magnet placement to attach the chin piece which is expected to need be removable to get helmet on / off

The cavity for the insertion of LEDs in the side of the Jowl.


Magnets used are 3/8 x 1/10 99K32.03


Placed in 3/8 steel cups 99K32.52


Jowl Insert STL, are for simple insert with recess for the RGB candle from


Which I just use to look at aesthetics.


I am running a replicator 2.

All sliced via makerware and standard latest makerbot firmware.

0.2 mm layers, with support and raft.

Please pay close attention to the orientation of pieces in the photos showing successful prints, as this is critical to the reduction in support implications, and surface finish.

Uses 1/8 x 3/4 tension pins for location of pieces to each other, except in one case on back corner where 1/8 x 5/8 pins are required due to clash.

License: Creative Commons – Attribution – Share Alike

Tags: halo