My Armor Build

[Chunk[501st]]

Hey All,

Well after having my FX kit sit in my bedroom for almost 3yrs to the day. I"ve begun putting it together. I masked off the legs & forarms. I've sanded the joining parts, & trimmed the excess off the theighs. I applied the glue to one of the calves. Now Im at a stand still as I wait for the glue to dry on this piece of armor. I used 6 diffrent clamps to hold it closed.

 

I used E6000 to glue the front seam of the legs. I'll have to shim the rear. I wanna velcro the shim in, just incase there is a weight change. I'll post more updates as I get to them

[zsavk[TK]]

Must see pics

 

But glad you are getting into it!

[Chunk[501st]]

Off to the room to take pics... Will post in a bit

[Chunk[501st]]

Here are some pics of me statring my build. Disreguard my mess. I woke up took a shower, kissed the wife & told her I'd see her some time later. I didn't want to be disturbed. She's just glad I actually started on my armor.

[pandatrooper[TK]]

I'm so jealous of those long C-clamps! Those would have made my build much easier! Nice work so far!

 

Before you get too far, make sure to wear socks and your TK boots for test fitting. I did that with my right shin and assumed the same measurements would work on my left shin - nope. I had already cut them and glued them, so I had to do a lot of heating and shaping with a heat gun.

[GosHawk[501st]]

Very cool man! I hope your not going to retire your tie pilot heh.

 

Btw where did you get those long clamps? Home depot? Lowes?

[Chunk[501st]]

I just glued the front seams. The backs are open, I need to shim the rears. The long clamps are what held me up all this time. I always wanted to glue them. I knew someone had to make "deep" clamps. I got them at Harbor Freight $6 ea. I modified them a bit. I taped a 1" Lego brick on the "hand" part of the clamp. It fits just right into the under seam of the armor.

 

NEXT QUESTION... The E6000 says it takes 24-72hr to cure. Due I have to leave the clamps on for minimum of 24 hrs? Or can I remove them & just let the armor sit with out touching it for the next few days. I'd rreally like to get to another armmor part

[pandatrooper[TK]]

I usually just clamp the stuff overnight. By then the bond is good enough to hold the parts together. I wait 24 hours before I stress the parts too much (eg: open the shins and stick my leg in).

 

I bought enough clamps to work on 2 pieces of armor at once. one set makes the build go really slow otherwise!

[Chunk[501st]]

Very cool man! I hope your not going to retire your tie pilot heh.

 

Btw where did you get those long clamps? Home depot? Lowes?

Hi Eric,

Nope the Tie Is my favorite right now. Its so comfy, I can wear it for long periods at a time.

I bought the clamps at HARBOR FREIGHT. I belive I got them on sale for $6 or $7 each. Regular price was $9. I knew someone had to make deep clamps. I searched the internet for years, I made trips to Lowes, Home depot, Walmart, small hardware stores & even Harbor Freight & nothing. Then one day I was looking for something else at HF & boom there they were I bought them right there & then. Wasn't gonna take a chance of them not being there the next time. But now Im thinking I should have got another pair. Ohh well live & learn, maybe I'll make a trip down today & pick up a 2nd pair.

Edited April 12, 2010 by Chunk

[pandatrooper[TK]]

Or you can use rare earth magnets on both sides too

 

 

[Chunk[501st]]

If anyone needs these deep clamps & doesn,t have Harbor Freight in their town. I can pick them up & mail them to you. They are heavy, but I can fit maybe four into a "one price" post office box. Last time I checked that was $9.95 any where in the United States. If you need more I'll have too step up to the larger box, which I think is $14.95. I can probably get up to 8pr in that box. I wont be able to get any til the 1st of May. I work for the state of california & get paid once a month

[Chunk[501st]]

Ok, just got back from Harbor Freight the clamps are $6.99ea. I bought two more & a few other various spring clamps. I glued the other calve, & will knock out both forearms when I get back from dinner. Assembling is addicting

[Chunk[501st]]

Ok, both calves are done. I just finished glueing the biceps together. I ran out of clamps again. Sheeesh I guess you can never have too many clamps. I normally use about 6 clmaps on each piece. Tomorrow I'll knock out both forearms. But all is comming together

[PGHtrooper21]

I just glued the front seams. The backs are open, I need to shim the rears. The long clamps are what held me up all this time. I always wanted to glue them. I knew someone had to make "deep" clamps. I got them at Harbor Freight $6 ea. I modified them a bit. I taped a 1" Lego brick on the "hand" part of the clamp. It fits just right into the under seam of the armor.

 

NEXT QUESTION... The E6000 says it takes 24-72hr to cure. Due I have to leave the clamps on for minimum of 24 hrs? Or can I remove them & just let the armor sit with out touching it for the next few days. I'd rreally like to get to another armmor part

 

I am after a Winter hiatus gluing my AP thighs now. I am using Retangular magnets from "Home Depot" I was using the circular haevy duty magnets from Joanne Faberics. They were a pain they kept fying off and my fingers and hands were getting pinched and bloodied.

 

After 24 hours I take the clamps and magnets off. It says the Temp range to use is between 70-80 degrees. I have used it between 40-80 degrees F.

 

The problem with E6000 is the strong fumes. When I come in the house the fumes are on my sweatshirt.

 

The stuff is GOOD!

[Chunk[501st]]

I am after a Winter hiatus gluing my AP thighs now. I am using Retangular magnets from "Home Depot" I was using the circular haevy duty magnets from Joanne Faberics. They were a pain they kept fying off and my fingers and hands were getting pinched and bloodied.

 

After 24 hours I take the clamps and magnets off. It says the Temp range to use is between 70-80 degrees. I have used it between 40-80 degrees F.

 

The problem with E6000 is the strong fumes. When I come in the house the fumes are on my sweatshirt.

 

The stuff is GOOD!

Fuems, what fuems? Im lucky in that department. My nose does not work at all. I can't smell a thing. So if there are fuems, my wife hasn't said a thing about them. Im doing my glueing in the bedroom because we've had storm roll in the last couple days.

[Chunk[501st]]

Ok, just got on the list for the VaderDave ab button kit. I din't know the FX kit has the wrong size buttons I learn something new here everyday.

My build is comming along nicly. Calves, theighs, biceps all glued. Im about to start on my forearms now.

[Chunk[501st]]

Ran into my fisrt SNAFU today. I went in the bedroom to remove the clamps from the theighs. The 1st was good. The 2nd was not It must have shifted when I set the piece down with all the clamps. The bottom was glued in the right position, but the top had moved about 1/4". I wasn't sure if I was able to pull them apart. But luckily I had just read on here that E6000 can be seperated if your carful. Well I looked it over, & got out my exacto knife. Slowly I inserted the blade in between both halfs. I took my time, not wanting to rush. I didn't want to push too hard or fast & have it slice open the other front seam to the armor. Concentrating, sweating, & a few silent cuss words & I was able to seperate it without breaking either half. Now Im off to remove the old glue & then reassemble. The forearms are gonna hve to wait til tomorrow

[Chunk[501st]]

Just ordered VaderDaves Ab Button replacement kit

[bluehickey]

Ok, just got on the list for the VaderDave ab button kit. I din't know the FX kit has the wrong size buttons I learn something new here everyday.

My build is comming along nicly. Calves, theighs, biceps all glued. Im about to start on my forearms now.

 

Hey Chunk, how old is your FX armor? I ask because I bought mine back last July, and the kit had been updated so that smaller silver screws were included that you paint to use as the buttons. They are the correct size. Here are what mine look like:

[Chunk[501st]]

I bought my FX kit back in June of 2007. It was my wife's BDay gift to me. I've had it sitting in the box for almost 3yrs now collecting dust. With a lil pushing from my fellow Pilots in the JRS. Ok so they were making fun of me for having it sit so long. I got to it at the end of my vacation last week.

[pandatrooper[TK]]

Ran into my fisrt SNAFU today. I went in the bedroom to remove the clamps from the theighs. The 1st was good. The 2nd was not It must have shifted when I set the piece down with all the clamps. The bottom was glued in the right position, but the top had moved about 1/4".

 

This is why I tape the parts together to prevent them from moving while the glue cures.

[Chunk[501st]]

I saw pics with the tape. I may add the tape to this leg. For some reason it continues to seperate after I apply the clamps. I've made some adjustments to my "tools" & will attempt to glue later

[Chunk[501st]]

Ok 2nd theigh all glued & ready.

But here is my next question. Im at the thermal det/o2 canister. I really don't like the 2 halves that came with my FX kit. Since day one I''ve always thought of replacing this one item. The two havles do not match up completely. I can get the edges even, but when I put the end caps on. I get a gap the length of the whole canister on top & bottom. I would really like to replace this with maybe a 2" pvc pipe. Im thinking this would be one piece, & I could make it to where I can remove one of the end caps to make a stormie wallet? What ya think? Im open to suggestions, as I can not get to this part of the build for a few days.

[Chunk[501st]]

Found this & wanted to have quick access to it

http://forum.whitearmor.net/index.php?showtopic=9645

[pandatrooper[TK]]

A lot people just replace the FX 2 part one by getting a section of 2.5" pipe, and assembling as described in the pictures / film reference.