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Team Armor Build [NE]: ESB in Northern California


Haribon72

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

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

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

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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
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Lower Legs

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

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

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Here are two legs (side by side).

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One is shows 10mm

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One shows 5mm.

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Edited by Haribon72
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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).

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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).

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Edited by Haribon72
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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.

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We want 10mm on each side.

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

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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.

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Ready for the clam shell fitting this weekend.

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Edited by Haribon72
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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). 

 

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Edited by Haribon72
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Ammo pack for the thigh.

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Done.

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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 . . . 

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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. 

 

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

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Let's prepare the forearms for Bingo.

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Reference reminder.

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Identifying the left forearm.

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Left arm has eleven square dips.

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Edited by Haribon72
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Right arm has twelve square dips.  Yes, I know these are ANH references, but it just makes sense to get the forearms identified. 

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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.

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Done.  Set aside for now. 

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Shoulder Bells.

Jingle Bells.

la la la la la!

 

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The swoop going to the left the left. 

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

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