So, how does this sound in terms of changes...
Remove minor armor variants, replace with decals (which work on most/all sets)
Make visors color customizable (no req) but add visor patterns, decals, and HUD REQs.
Break armor back down into components. Helmet, shoulders, chest piece, gauntlet, greaves, boots. Maybe combine those last two. Yes, not all pieces will play nicely together, and some will clip, but if that bothers the player they can just... pick other pieces, lol.
Brand new reqs should include win poses, emotrs, and, to outright steal somebody else's idea, vehicle customization reqs for Warzone which sounds fantastic.
Each REQ unlockable by 3 means: commendations, direct purchase through REQ points/cash, and packs. Items attached to higher-difficulty commendations have higher direct ourchse costs, which are always higher than the REQ cost of a pack. Direct purchase dollar cost should probably be as cheap or cheaper than a pack, to avoid outrage. Gameplay reqs should probably stay in packs, but maybe makensome loadout weapons available for direct purchase with points isn't a bad idea.