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Captain Rex's phase 2 helmet (when he finally gets one) appears to use a phase 1 visor style, with it being thick at the nose and tapering towards the ears, while the standard phase 2 helmets start thinner at the nose and expand to make a larger blob around the eye.

Standard phase 1 helmet:

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Standard phase 2 helmet:

enter image description here

Rex's Phase 2 helmet:

enter image description here

If you look closely around the nose part of his helmet, it almost looks like there's a line where a phase 2 face-plate was welded to a phase 2 helmet, but even if that's the case, it raises the question of why Rex would do and be allowed to do that. Why did he use such a strange helmet?

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    To distinguish him from the other nearly identical soldiers when the audience are looking at him with his hat on. – Valorum Aug 19 at 0:30
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    @Valorum I was more looking for the in-universe reasons, though out of universe answers are welcome too – cat40 Aug 19 at 1:18
  • In-universe: Even in the picture given (and seen in canon materials), we can see that the clones obviously have some leeway when it comes to the condition of their gear. They can apparently write, draw, and customize their stuff. Also - rank hath it's privileges – NKCampbell Aug 19 at 16:07
  • A somewhat in-universe answer would be that Rex was a high-ranking clone trooper and therefore had a bit of room when it came to keeping/modifying his own equipment. It might also be worth noting that Rex's modified helmet might have added benefits such as added visual and audio sensors, lighter weight or additional protection, but this is just speculation on my part :-) – Boolean Sep 22 at 7:47

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