Jump to content

Recommended Posts

Posted (edited)

Re-use the cut out as an inside joint cover and backing.   Glue this piece only first and let it set over night.

IMG_6281.JPG

 

Sand off both sides of the cut off.    Make trims on the ends if necessary.

IMG_6282.JPG

 

Glue, clamp, magnets, and let it cure overnight.

IMG_6283.JPG

 

Continue the same process on the other thigh, finish it up, and call it a night.   I used blue painters tape to keep the ABS cement from leaking to the front of the thighs.  Right now there is no cover strip to the front.   There's a reason to my method.  Bingo wasn't around this evening.   So we'll continue the thighs this weekend.

Edited by Haribon72
  • Like 1
Posted (edited)

Lower Legs

This how I build them in preparation for fitting.  This is the same process as the thigh assembly.

IMG_6310.JPG

 

This is how I identify the left and right lower legs.  The CRL shows a bigger return edge on the left leg.

IMG_6311.JPG

 

Here are two legs (side by side).

IMG_6313.JPG

 

One is shows 10mm

IMG_6318.JPG

 

One shows 5mm.

IMG_6319.JPG

Edited by Haribon72
Posted

The legs with 10mm edges, I will use them as the left lower leg.

IMG_6315.JPG

 

The legs with 5mm will be the right leg (with the ammo pack).

IMG_6316.JPG

Posted (edited)

Cutting.

 

Measure from the top of the ankle to the bottom of the knee.

Mark the armor and cut all of the bottom off (following the old curvature).

IMG_6323.JPG

IMG_6324.JPG

 

The distance between Bingo's top ankle and bottom of his knee is 12.5 inches.   (The actual distance was 13.0 inches but we removed 1/2 inch more for the TK boots clearance).

IMG_6325.JPG

IMG_6326.JPG

Edited by Haribon72
Posted

Next, remove the return edge of the top of the armor.  We don't need it.

IMG_6329.JPG

IMG_6330.JPG

 

Use a strong utility knife for cutting.

IMG_6331.JPG

Posted

Next, we're going to cut off the front part of the lower leg to make a 20mm butt joint.

I'm starting from the inside again because it has a clean line for measurement.

IMG_6334.JPG

IMG_6335.JPG

IMG_6336.JPG

 

We want 10mm on each side.

IMG_6337.JPG

Posted

Sand it down using our home made belt sander.

IMG_6338.JPG

IMG_6339.JPG

 

We saved our cut out piece to make our 20mm cover strip for the inside only!

IMG_6340.JPG

Posted (edited)

Glue the cover strip to the inside (don't forget to sand it down before gluing).

IMG_6341.JPG

IMG_6342.JPG

 

Once you finish gluing the lower legs together, the armor will need to set overnight.  Again there's no cover strip to the front lower legs.

We are creating a clam shell for Bingo to put his legs into so we can get a nice measurement before we trim the back of the legs (lower and thighs).

That's the idea to my method.

IMG_6343.JPG

 

Ready for the clam shell fitting this weekend.

IMG_6345.JPG

Edited by Haribon72
Posted (edited)

This is the ABS cement i'm using.  It came with the kit.

 

You can buy this cement on Amazon:   WELD ON 771 ABS (make sure its MILKY color).

 

Note:  This cement is strong with a cement odor when wet.  After it dries, the odor is gone.   After applying it, it takes about four hours to cure and set.    Overnight is best.

If you need to remove or disassemble an armor piece, you will be using a chisel and light hammer to separate the cement bond.  I like this cement because it will hold better than E6000 (also I can't stand the smell of E6000 - even after it dries). 

 

IMG_6344.JPG

 

IMG_6347.JPG

Edited by Haribon72
Posted

Let's work on the sniper knee.

IMG_6349.JPG

 

I'm going to leave 7mm at the top of the knee.

IMG_6350.JPG

 

Adding more cut out areas to give it a movie look.

IMG_6351.JPG

Posted

Best way to cut it off.   

 

1. Solid surface

2. One by four wood

3. Sharp utility knife

4. Patience (take your time)

 

IMG_6354.JPG

IMG_6355.JPG

 

Burr the edges and sand.

IMG_6356.JPG

IMG_6357.JPG

 

Done.

IMG_6359.JPG

Posted

Ammo pack for the thigh.

IMG_6360.JPG

 

IMG_6361.JPG

IMG_6362.JPG

 

IMG_6363.JPG

IMG_6364.JPG

IMG_6365.JPG

IMG_6366.JPG

 

Done.

IMG_6367.JPG

 

We're going to heat bend the ammo pack this weekend.  We don't want to bend it now because we still have to clam shell the thighs on Bingo.

 

Okay.. have a great evening (or day).    To be continued . . . 

Posted

Let's paint the Ears.

We decide to paint the ears first and then install them later.  Its easier to paint them seperate rather than on the helmet.

I purchased a punch set to make perfect circle as stencils. 

 

IMG_6376.JPG

IMG_6377.JPG

IMG_6380.JPG

IMG_6381.JPG

IMG_6382.JPG

IMG_6383.JPG

 

We want to use a quarter of the circle to get clean curves.  

IMG_6384.JPG

Posted

IMG_6424.JPG

IMG_6426.JPG

 

Time to add the grey.

IMG_6427.JPG

IMG_6428.JPG

 

Allow to dry overnight and we will re-visit with an exacto knife to clean off the smear marks.

IMG_6429.JPG

Posted (edited)

Let's prepare the forearms for Bingo.

IMG_6401.JPG

 

Reference reminder.

IMG_6387.JPG

 

Identifying the left forearm.

IMG_6390.JPG

IMG_6391.JPG

IMG_6395.JPG

Left arm has eleven square dips.

IMG_6396.JPG

Edited by Haribon72
Posted (edited)

Right arm has twelve square dips.  Yes, I know these are ANH references, but it just makes sense to get the forearms identified. 

IMG_6397.JPG

IMG_6398.JPG

IMG_6399.JPG

Edited by Haribon72
Posted

Next, we size them up to Bingo's forearms (length first).  We will remove the wrist and elbow areas later.

IMG_6407.JPG

Posted

Biceps.

Identify left and right. 

IMG_6408.JPG

 

Size them up to Bingo's biceps.

IMG_6411.JPG

 

Cut. 

IMG_6413.JPG

 

Cut off the return edges.

IMG_6415.JPG

Posted

With the bicep cut-outs, we made the j-hooks.    Now there's a lot of discussion about the hooks for ESB.    We're going to make and add them for trooping use and avoid any further discussions.

IMG_6430.JPG

IMG_6431.JPG

IMG_6432.JPG

 

Done.  Set aside for now. 

Posted

Shoulder Bells.

Jingle Bells.

la la la la la!

 

IMG_6487.JPG

 

The swoop going to the left the left. 

IMG_6488.JPG

 

Added snaps and labeled them for easy identification.  Set aside for now. 

IMG_6488.JPG

IMG_6492.JPG

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...
×
×
  • Create New...