Halo Reach Assault Rifle Build

[bluerealm]

I decided to take on a new project and I wanted to share it with the group. Most of you will recognize this weapon from the new halo reach game.

First we needed a 3d model. RSloan76 hooked me up with a beautiful rendition of the rifle, and I took the model and imported it into SolidWorks for some fine adjustments and to prepare the model for milling.
YouTube - Blue Realm Studios Assault Riffle Model

Then I setup all the tooling paths for CNC machine.
YouTube - Blue Realm Studios Assault Rifle Tool Path


Once the tool paths are configured for all the pieces I started milling the sucker out. Check out this cool video MjolnirArmor put together for me. The video really shows the process of milling and how the pieces get made.
YouTube - Blue Realm Studios- Halo Reach Assault Rifle Making


Now that I've milled out most of the pieces its time for some finesse... The CNC machine does a great job of getting the pieces to a good working stage, but it’s now up to me and some good old fashioned sandpaper and bondo to really make it come together.

The material I used is called sign foam. It’s dense urethane foam and works great for projects like this. It’s easily sanded and glued with some pvc adhesive.

After gluing up all the pieces and fine tuning the detail I'm going to try and seal it up and do some nice wet sanding to give it that nice metal texture. This is a time consuming process but I wanted to go ahead and show the progress I've made so far and I'll keep you guys up to date as the project continues.

You can check out this and more on my blog at Blog | Blue Realm Studios

 

[Luke]

This is awesome. Incredible detail. May I ask what program was used for the initial 3d model?

 

[bluerealm]

Sloan Hood (RSloan76) created the orginal model in 3d Max.

I'm better in Solidworks and we needed to make some fine adjustments to scale and what not based on the image I found from bungie.

Here is mine as an overlay.

 

[Luke]

Way cool. That is a gorgeous 3d model. As a 3ds Max user myself, I was curious to see what the transition was. That is an inspiration. I don't have much experience with Solid Works, but I'm well versed in Inventor. I'm a graphic designer for a small sign shop and occasionally we sub-out to another company for cut foam letters. I'm interested now if they too have the capabilities to do detailed cnc work on the same material.

Any idea what the casting capabilities of that foam are? Do you have plans to use your model as a mold of any sort?

 

[bluerealm]

Way cool. That is a gorgeous 3d model. As a 3ds Max user myself, I was curious to see what the transition was. That is an inspiration. I don't have much experience with Solid Works, but I'm well versed in Inventor. I'm a graphic designer for a small sign shop and occasionally we sub-out to another company for cut foam letters. I'm interested now if they too have the capabilities to do detailed cnc work on the same material.


Any idea what the casting capabilities of that foam are? Do you have plans to use your model as a mold of any sort?

Most sign companies have the capabilities, but you'll probably need to go to a rapid prototyping company for any type of detailed milling work. The modeling and the tool path generation are the hardest parts.

I started with 3d max way back when in school, but I've grown to love solidworks as it’s more of an engineering tool than and artists tool. So you get all those nice sharp edges and smooth transitions on mechanical parts.

Once the master has been sealed up and sanded smooth and coated with primer and clear coat. It will be prepped for molding. I'll probably keep a few parts separate to make for a easier molding, like the magazine and scope. Then I'll just cast the weapon out of smooth cast or something and add all the finishing details and paint job.

 

[Luke]

Really impressive stuff. I am a big fan of this.

Any plans for electronics in the final product?

 

[1up89]

SOLD lol yea i like it if you do sell PM me. :rolleyes I will 1st in line put out a number

 

[bluerealm]

Really impressive stuff. I am a big fan of this.

Any plans for electronics in the final product?

I thought about it.. Probably not for the first round... but I'll probably come back to that. I just started learning the arduino platform and think it might be a good way to go.. but I'm not an electronics guy by any means. But I've been playing with lcd's and sound modules a bit.

SOLD lol yea i like it if you do sell PM me. :rolleyes I will 1st in line put out a number

LoL... you got it... I'll keep you up to date.

 

[Volpin]

Brilliant work, but I'd expect no less!

You guys with the fancy tooling really make me jealous

 

[bluerealm]

Brilliant work, but I'd expect no less!

You guys with the fancy tooling really make me jealous

LoL... Thanks Volpin

You should build one.. Thats what I did.. I couldnt afford the fancy out of the box ones.. Took me a few years, but I'm finally happy with the results of it.

I could definatly use your help with the electronics.. I'll give you a free AR if you help me out.

 

[ALPHA D UNIT]

I couldnt afford the fancy out of the box ones.. Took me a few years, but I'm finally happy with the results of it.

Build it!? :confused

Specs!!!!!

 

[bluerealm]

Build it!? :confused

Specs!!!!!

That’s a little off topic but for the shear pride of my baby I'll indulge. It’s a 3 axis rail guided belt driven/rack and pinion x y system mounted on 8020 frame. The z is driven by a belt drive gear box (bent sheet metal) controlling a lead screw. I used a k2cnc router mount to hold my 892 porter cable router. The bed is t slot rails with mdf spoil boards. It has a working area of 24x36x6. It’s on top of a chop top kobalt workbench enclosed by my custom wood box with lexan doors. That helps keep the dust and noise down. It uses 4 470 oz/in stepper motors, 4 driver boards, breakout board, and 48v power supply, 3.6 ghz controller pc running mach 3 controller software. Wooshh… that’s about it.

So we don’t get to far off topic, I’m no CNC expert I just picked it as a project and built one… It’s taken me two years to be happy with it.. This AR will be my second real project using it. I don’t suggest building your own if you are just the general hobbyist… Find a friend like me that has one and make him do stuff for ya. : )
But if you have specific questions about it PM and we’ll talk about it off topic.

 

[Luke]

How does the clip attach to the rifle? Any catch mechanism in mind?

 

[bluerealm]

How does the clip attach to the rifle? Any catch mechanism in mind?

Honestly I haven't thought about it too much. My initial thoughts were to just use some earth magnets.. That way it will stay in there until you give it a good tugg. I'm sure I could figure out some type of latch system, but things change when your dealing with a hollow slush cast.

 

[Volpin]

LoL... Thanks Volpin

You should build one.. Thats what I did.. I couldnt afford the fancy out of the box ones.. Took me a few years, but I'm finally happy with the results of it.

I could definatly use your help with the electronics.. I'll give you a free AR if you help me out.

haha, sold! drop me an email (I know you did like, ages ago back before my wedding) and let me know what you're after. I'd love to help out.

contact@volpinprops.net

 

[Luke]

Honestly I haven't thought about it too much. My initial thoughts were to just use some earth magnets.. That way it will stay in there until you give it a good tugg. I'm sure I could figure out some type of latch system, but things change when your dealing with a hollow slush cast.

Magnets would probably be the easier choice, considering the fact that the mold will be hollow. Maybe a stand alone clip mechanism that's molded to fit in that area would be cool. Which could also use magnets, lol.

What type of glue do you use to adhere the foam pieces together?

 

[bluerealm]

Magnets would probably be the easier choice, considering the fact that the mold will be hollow. Maybe a stand alone clip mechanism that's molded to fit in that area would be cool. Which could also use magnets, lol.

What type of glue do you use to adhere the foam pieces together?

Yeah that was my thoughts too..

I used some of that all purpose cement from home depot. Its in the PVC cement section. It said abs, and had other poly's listed so I grabbed it. Works great.. Super hard bond.

 

[Luke]

It's funny, I've been playing Halo since it came out and never once did I consider the fact that the Assault Rifle has no sights.

 

[bluerealm]

It's funny, I've been playing Halo since it came out and never once did I consider the fact that the Assault Rifle has no sights.

Haha... I just assumed that one thing above the barrel was a laser/infrared pointer that transmited the crosshairs to the HUD in the helmet. Actualy I just made that up... I never thought of it until now.. But its a good guess right?

 

[RSloan76]

Yup, this is coming along great. I'm calling dibs on painting the first cast

Not much else to say other than it's as badass in person as it is in the pics. Perfect size. Feels great in your hands.