Team Armor Build [NE]: ESB in Northern California

[Haribon72[TK]]

Gloves and ESB handplates.

Reference check.   Bingo picked these up at OSH hardware store in the house cleaning aisle.  

 

EDITED ON 11/12/2015.  We have abandon the chemical gloves for this project.   We have updated to black silk gloves.

Link here:  http://www.whitearmor.net/forum/topic/33467-team-armor-build-ne-esb-in-northern-california/?p=440047

 

Edited November 12, 2015 by Haribon72

[Haribon72[TK]]

I've never worked on ESB hand plates.  So were doing some reading.

[Haribon72[TK]]

[Haribon72[TK]]

We decided to freestyle it and shape to Bingo's hands.

 

NE armor is tough to cut.   It took several minutes to cut. 

 

More shaping.

 

Done.  Set aside for now.

[Haribon72[TK]]

As he was cutting, I was sewing his velcro straps.    Yes, I'm learning how to sew. 

[Haribon72[TK]]

Morning came and he wanted to do a test fit with my ANH stunt helmet.  On this day, we had garrison members help with the arms and legs (mostly sizing, shaping, cutting, sanding, beer, laughs, jokes, Star Wars talk, and BBQ. 

 

Bingo installed the mesh screen for the frown using hot glue.   Nothing fancy.  

I recommend your paint your inside bucket black so it won't show the hot glue work from afar.

Edited May 17, 2016 by Haribon72

[Haribon72[TK]]

How To Work the Back of the Thighs and Lower Legs

 

Okay.... there's a purpose to my method with the thighs, lower legs and arms.   Earlier in our thread, we left the back parts untrimmed.   Now that we have a full day, Bingo is going to wear the center core to get use to the plastic costume.    While he's wearing it, we will put on the leg and arms to get his final fitting.   This is the perfect time to get the right measurements before trimming and gluing.   

 

We created a "clam shell " phase on the thighs and legs.   This makes it easy to fitting, mark, and trim. 

 

First we measured the length (without boots).  He has muscular calves so we want to add comfort first.

Then we cut them down and added the boots to get the final fit.

Edited May 17, 2016 by Haribon72

[Haribon72[TK]]

Sorry, I didn't take much pictures of the arms and legs build.   The day went on... and I think the BBQ short ribs and beer (kinda) slowed us down. 

Here are the day end pics I took of his 85% finished lower legs.   We will add the 20mm finish strips and the sniper knee on our next session.

 

The lower legs have the butt joint requirement with white velcro to hold them together.   Okay....to be continued.

Edited October 21, 2015 by Haribon72

[Haribon72[TK]]

Re-visiting the Ab and butt plate assembly.

We're going to eliminate the flapping butt plate and tighten up "family jewel" area.    We really need that bottom ab area to pull in the butt plate.

We also had one of the strapping brackets break the armor.  So we will be showing our repair work.

 

Done.

[Haribon72[TK]]

Repair work on butt plate and strapping bracket.  We used left over plastic, cut to size, sand and glue.

[Haribon72[TK]]

Completed some heat bending and shape.  Here's the finished look.

[Haribon72[TK]]

Final Fitting Stage
Center core is done.
Arms and legs are now in the clam shell stage.

We can now get proper measurements, mark, cut, sand, and glue.

 

In this stage, I had Bingo do the following exercises without a helmet:

1. Put on and take off the helmet.
2. Walk around the house (smoothly).
3. Walk up a few steps (not stairs).
4. Bend down to tie a shoe.
5. Reach for the blaster, pose, and put the blaster back  into the holster.

 

We are identifying all the discomfort spots and restrictions. 
Marking everything with a pencil and cutting away the armor down to his body size for final fitting.
Notice, we did not put on the final cover strips yet. This can be done later (after the final final final fitting).

 

" Measure three times.... then CUT! "

 

If you have a friend to help, this is where you need it the most.

 

Edited October 27, 2015 by Haribon72

[Haribon72[TK]]

An evening goes by with trimming and gluing.   Here are some finished armor (before the cover strips are installed) with shaping to his body.

[ukswrath[Staff]]

Just like a fine tuned machine, excellent work you guys 

[Haribon72[TK]]

Biceps done.

[Haribon72[TK]]

Installing the Ammo Pack to the Thigh - Part One

Note:  This is NE armor.   The installation principle is the same, but always check your armor measurements before proceeding.

 

 

Here's a new trick to keep the ammo pack from dancing around or breaking off.

Let's make a box holder inside the ammo pack.

 

Using left over cut outs.

 

This is the model cement I used to build the box - Tamiya Extra Thin Cement.  You can buy this on Amazon or eBay.

I discovered this cement from the Clone Trooper builders (another 501st Legion detachment).

 

Edited February 18, 2016 by Haribon72

[Haribon72[TK]]

 

Let the new box set for a couple hours.  For the top cover on the box, I used ABS cement. 

Edited October 26, 2015 by Haribon72

[Haribon72[TK]]

While the ammo pack is hanging out, let's work on the sniper knee.

 

Sand down the lower leg.

 

Sand down the knee plate.

 

Glue.

 

Just a gluing refresher note:

Since NE has a glossy finish, please be sure to sand down the gloss and gluing areas.

This principle is the same as plumbing PVC pipe installations.    Measure, cut, sand, and glue.

Edited October 26, 2015 by Haribon72

[Haribon72[TK]]

Just like a fine tuned machine, excellent work you guys

Thanks Tony! We just had to lay off the beers for these sessions. Hahhahaha!

[Haribon72[TK]]

Now if your sniper knee breaks off, here's the fix.

Time to bring out the heat gun.

 

Heat up the area and throw in your clamp right away.   Let the clamp work the soften area towards the knee plate.

 

Allow the clamp to work on the armor for about ten minutes, remove the clamp, glue, and re-clamp.

Let it hang out for a couple hours (or overnight).

[Haribon72[TK]]

Installing the Ammo Pack to the Thigh - Part Two

Now that the special box to the ammo pack had time to set, let's finish it off.

Here's my high end knee bender kit.

 

Heat, bend, heat, bend, heat, bend . . . .  Done.

Edited October 26, 2015 by Haribon72

[Haribon72[TK]]

Special box is doing well.  

 

Let's install the ammo pack (finally).

 

Marking the cut off point (this is the side facing outside the thigh).  We are going to keep the length on the inside thigh).

 

[Haribon72[TK]]

Here's a new trick!

 

Find yourself a spice lid.

 

The spice lid is a great match for the ammo pack.  We are going to make the rounded cut off.

 

Cut off, sand, and polish.

[Haribon72[TK]]

Time to mark your pilot holes on the ammo pack.

[Haribon72[TK]]

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