Noah's RT-Mod ESB build

[NastyNoah[TK]]

More progress

 

I have been working away on different parts of my armor today since about 10 am. Decided to take a quick break to update this thread and do some more research before I begin gluing on my snaps.

 

Trimmed about 1/2 inch off the back of the thighs to get a snugger fit and glued them up. I have now completed all the clam shell type pieces.

 

Attaching the sniper plate to the sides was made possible with the use of 6 clamps and some patience.

 

 

The sniper plate is one piece that really needs to be reworked to fit better.

 

Snap plates.

 

I am going with a mix of standard plastic snap plates and the webbing ones. For the webbed plates I used an old guitar strap I had lying around that was 2" wide. I cut it up into about forty strips then seared the ends of the strips with my trusty propane torch.

 

I am sure they will not fray at all.

One I completed the searing I plugged in an old cheap Radio Shack solder iron to use as the punch. The soldering iron worked perfect and was very fast but I don't recommend doing it inside unless your wife is gone and you have the windows open. It does create some smoke and puts off a foul stench similar to Governor Tarkin. But the size hole it creates is perfect and since it is melted it will not fray.

 

Now it is time to set some snaps.

 

Only 20 something left to make. I have noticed the snaps don't get a good grip on the webbing like the ones I did using the plastic. I don't think this will cause any problems but if any of you with some experience know other wise please let me know before I get to much further.

 

Ab buttons.

I found this bag in the bottom of my brown box and at first was unsure what they are for. I now realize these are the ab buttons. I drilled some holes in a 2X4 simulating the lay out of them on the armor.

 

 

i then used some gray primer to get them ready for the Testors paint and while I was at it I painted my TD at the same time.

 

I have now learned that the primer does not stick to these little plastic pieces at all. It wipes right off with a finger. I will have to try another route with these.

Edited March 26, 2012 by NastyNoah

[NastyNoah[TK]]

One week ago today I received the big brown box and in that time I believe I have accomplished quite a bit on this build. I am already starting to wonder what I am going to do once it is complete. I have spent the last three months researching this project in anticipation of starting on it and now I know I will be done here very soon and right now I am too broke to start on another kit.

Any ways I was able to glue the thigh pack on after some trial and error. I had to drill out the RT rivet bumps and into the thigh seam where I put a temporary fastener in to hold everything in place.

 

I then applied the E-6000 to every point that made contact with the thigh, and clamped it down.

 

 

I started on some strapping tonight and plan on doing quite a bit more tomorrow after another trip to Tandy leather.

[jnnfr72[TK]]

Looking good, Noah!

I can't wait for you to replace that crazy screen pic with one of you in your armor. haaaa haaaa!!!!

[darksideemt]

2 things

 

1- why did you use webbing for snap plates? will they hold as well as plastic? i ask, because i havent seen this before and i am curious.

 

2- you will want to put a healthy bead of e6000 over the rivets on the back of the belt. they rub your belly armor and scratch it up.

 

nice work so far!

Edited March 27, 2012 by darksideemt

[NastyNoah[TK]]

2 things

 

1- why did you use webbing for snap plates? will they hold as well as plastic? i ask, because i havent seen this before and i am curious.

 

2- you will want to put a healthy bead of e6000 over the rivets on the back of the belt. they rub your belly armor and scratch it up.

 

nice work so far!

 

1- I am using the webbing for the snap plates because I can get it affixed to the armor easier than the plastic plates. I am still using plastic snap plates in parts of the armor that are not curved or contoured. I'll post more pics of this as I progress.

 

2- I had not thought about the belt scratching up my armor. Thanks for the tip, I will take care of that tonight.

[NastyNoah[TK]]

Looking good, Noah!

I can't wait for you to replace that crazy screen pic with one of you in your armor. haaaa haaaa!!!!

 

I cant wait to replace my avatar as well, and add my TK id number to my postings.

[NastyNoah[TK]]

I have now tried two different kinds of primer and Testors paint and everything seems to rub off of these little plastic pieces very easily. Does anyone know a trick to get the paint to stick to these?

[xaoslord]

Have you tried scuffing them up with a green scouring pad or some sandpaper? That will give the primer a little something extra to bite on to.

[LadyInWhite[TK]]

Looking good! The sniper plate is a real slave Leia. Please don't rivet it. Use lots and lots of clamps and glue.

 

Agreed... it's the one thing I can't reverse for Centurion.

 

My sniper plate didn't fit exactly right either... I felt I had no option as no amount of clamp or tape seemed to keep it where I wanted it, so I riveted in desperation to get it to stay.

 

2- I had not thought about the belt scratching up my armor.

 

Yeeaah. I have tape on the back of my holster rivets. Fortuantely the snaps on the ab plate hold it still and it's not moving around a lot.

 

 

I have now tried two different kinds of primer and Testors paint and everything seems to rub off of these little plastic pieces very easily. Does anyone know a trick to get the paint to stick to these?

 

I painted testors onto the plastic directly with no primer, and have had no trouble. Are they ABS?

 

Great build thread, you are going so fast!!! Soon you can get back to those Lego builds.

[NastyNoah[TK]]

 

I painted testors onto the plastic directly with no primer, and have had no trouble. Are they ABS?

 

Great build thread, you are going so fast!!! Soon you can get back to those Lego builds.

 

The buttons are not ABS they are some kind of oily plastic caps. I am going to rinse them with water and dish soap tonight then slightly scuff with 400 grit paper. If that doesn't work I will just buy some of these off eBay.

 

http://www.ebay.com/itm/290656348177?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

[LadyInWhite[TK]]

Try here first?

 

http://forum.whitearmor.net/index.php?showtopic=16842&st=20

[NastyNoah[TK]]

Tuesday night update !

 

Took the clamps off of my thigh ammo belt and everything is looking good. Was able to add the split rivets and I am very happy with the way it looks. I would like to think everyone that commented and helped me out with this.

 

Made a ton of plastic snap plates tonight. First i drilled a hole all the way through each plate just large enough for a 1/8" rivet to go through. I then used a 1/4" bit to to make a counter sunk recess for the head of the rivet to sit in. I was able to rivet the male fasteners to the snap plate and it went a lot faster using the rivet gun over the snap setter tool. Using this method I can get more of the snap plate connecting with the glue and the armor pieces.

 

I should have taken some more pictures of this but I think everyone will understand.

 

I added the two male snaps to the but plate bu have not permanently fixed them to it yet. Let me know if this is correct before I make anything permanent.

 

 

The rest of my night was spent attaching snap plates to the armor.

Maybe I will be able to do a test fit by Friday.

[Eldrik]

Good work on that thigh ammo belt

[NastyNoah[TK]]

Good work on that thigh ammo belt

 

Thanks Jens, the thigh ammo and the sniper plate were difficult to get attached but I am grateful I took the extra time to do it and do it right.

[Griffin-X[TK]]

Great progress Noah! You are getting very close!

[NastyNoah[TK]]

Well Troopers not much progress was made tonight. I rushed on my plastic snap plates and didn't notice that on more than half of them the rivet head did not mushroom out enough. Tonight when I was doing my first test fit the buttons began to pop. I now know I need to put a washer inside of the snap or flatten the rivet head out a bit more with my snap setting tool. You win some you lose some... Oh well at least I learned a valuable lesson that I won't repeat. I have since put some of the webbing snaps in place and I am letting them cure. I think I can still do a test fit this weekend and that will give me a whole week to tweak everything before Easter.

 

I did go ahead and add the two male snaps to the crotch of the butt plate.

 

 

Thanks everyone for the kind words and support !

[Griffin-X[TK]]

Rock and Roll Noah!

[NastyNoah[TK]]

It's all in the details...

 

Finally felt confident enough to start adding little details to the suit tonight.

Accurate split rivets on the left side of the ab and kidney

 

Right side male snap on the upper left corner of the ab plate.

Functional male snap in the crotch.

 

And the split rivet in the crotch. How gansta is that ?!?!?!

 

Tomorrow I am going to install a suspender system and attach the thighs then I am moving up the body to the chest and back.

[Mopar McNeer]

Where did you pick up the accurate split rivots Noah?

[NastyNoah[TK]]

Where did you pick up the accurate split rivots Noah?

 

I got them off of eBay. Here is a link http://www.ebay.com/itm/130498261658

[Griffin-X[TK]]

BTW...I'm in the Star Garrison so you'll be part of the family soon.

[NastyNoah[TK]]

BTW...I'm in the Star Garrison so you'll be part of the family soon.

I can't wait to meet up with you guys !

[Mopar McNeer]

I got them off of eBay. Here is a link http://www.ebay.com/itm/130498261658

 

Pack of 100 eh? You have some extras that you would sell Noah? LMK. I'd like to get enough for a couple kits (me and a buddy's TK's). Send me a PM if you can help.

Thanks!

[NastyNoah[TK]]

Oh Snap... I ran out them again.

 

My build process is slowing to a crawl it seems. Tonight I planned on doing so much while my wife and son are gone but wouldn't you know it I am out of snaps again. I plan on hitting the local Tandy Leather in the morning and hopefully I can keep this build moving.

 

Things that I know I still need to do.

Put support straps in thighs

Make, or buy some TD clips

Strap chest and back

Install buttons on abdomen

Repaint the split rivets

and do more research.

If any one notices something I left off please point it out.

 

Now for pictures of tonight's progress

Installing suspenders. I used an old pair we had lying around, cut off the clips and installed female snaps. Cheap, quick, and easy just the way I like most everything.

Here is a picture of the snap I put in the shoulder bells to prove I still made some progress tonight.

 

I have updated this post to show more clearly how I am strapping the other pieces.

This is how I did the chest and back connections using EIB approved white 1" elastic

They float in back but I have a bit of velcro to secure them once fitted. Only do this if you are going for ESB or ROTJ

Glued in the front

 

Elastic strap that I run across my back to connect the shoulder bells

the strapping of the bells to the biceps

You can see how the strap runs across my back if you look very closely. I should have wore a white shirt to show this a bit better.

Edited April 9, 2012 by NastyNoah

[NastyNoah[TK]]

So I haven't updated this in a few days, but here is a list of things I have finished.

Painted the ab buttons

Added the ab buttons

Glued the ribbed shoulder straps to the chest piece

Drilled out the rivet and installed the 3rd screw in my RT helmet

Put the drop boxes on the belt

Painted the rivets

and now I am making adjustments to the elastic. I should have everything but the TD finished in time for Easter.

 

If you don't have to add the third screw I wouldn't. I ended up melting a hole through my helmet and pulling the rivet through. I fixed this by using a slightly larger screw and a washer.

I went with Testors for the buttons since it is easier to acquire and only $1.50 a bottle.

 

Detailed pics of the belt and accessories.

I slapped a piece of hook sided Velcro to the front of my ab plate to keep the belt in place.

 

WARNING !!!!!! If I had this to do over again I would use the loop side of the Velcro because when getting dressed you reach across your armor and it never fails I get my under suit snagged on the Velcro. When I re-do this I will probably go with snaps.

 

Its a bit hard to see in this picture but I applied the loop side directly to the belt after peeling off the backing and exposing the adhesive. I reinforced this bond with some E-6000.

I looped 1" white elastic over the belt then riveted it to the drop boxes. You can attach them many other ways but I wanted to get some use out of the rivet gun I bought.

Sorry about the picture quality here, just showing how my ESB holster loops over the belt.

Edited April 10, 2012 by NastyNoah