HOWTO: ukswrath's FO TK Battle/Riot Shield assembly

[ukswrath[Staff]]

Like we need another battle/riot shield build tutorial right? Enjoy

 

Battle/Riot Shield kit - http://www.whitearmor.net/forum/topic/34151-first-order-stormtrooper-battleriot-shields/

Kit - Main shield (1), Fogged plexiglas (1), Shield tips (4), Forearm mount (1), Custom decal (1)

 

Assembly Materials

1) Glue - E6000

2) Velcro, industrial with adhesive, 9" x 1", white, (2" shown for sale) - http://www.amazon.com/gp/product/B0006HWYJM?keywords=1%26%2334%3B%20industrial%20velcro%20white&qid=1453297413&ref_=sr_1_2&sr=8-2

Note: I took 2" velcro and cut it in half.

3) Velcro (sew in) 5" x 1", black, (2" shown for sale) - http://www.amazon.com/gp/product/B003L1PUKK?psc=1&redirect=true&ref_=oh_aui_detailpage_o07_s00

Note: I took 2" velcro and cut it in half.

4) Elastic, 12" x 1-1/4"  - http://www.amazon.com/gp/product/B015OPFF3C?psc=1&redirect=true&ref_=oh_aui_detailpage_o06_s00

5) Nylon webbing, 12" x 1-1/4" - http://www.amazon.com/gp/product/B014FXKDP4?psc=1&redirect=true&ref_=oh_aui_detailpage_o05_s00

6) Foam handle bar grip - (set of two from sold here) - http://www.amazon.com/gp/product/B0036GGB4Y?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s00

7) Neoprene Foam strip with adhesive or similar, 12" x 1-1/2" - http://www.ebay.com/itm/1-4-x-6-Adhesive-Backed-Foam-Rubber-NFR-25-6-AB-/261675202687?hash=item3ced0eb87f:m:m_DUnws5VNZDnvI1CBYgSxA

8) 1 Silver/Chrome spray paint - Rust-Oleum #1915830 - http://www.homedepot.com/p/Rust-Oleum-Specialty-11-oz-Metallic-Silver-Spray-Paint-1915830/100189098

9) 1 Satin Black spray paint - Rust-Oleum #265545 - http://www.homedepot.com/p/Rust-Oleum-Universal-12-oz-All-Surface-Satin-Black-Spray-Paint-and-Primer-in-One-6-Pack-265545/203188794

10) 1 Grey Primer spray paint - Rust-Oleum #2081830 - http://www.homedepot.com/p/Rust-Oleum-Stops-Rust-12-oz-Flat-Light-Gray-Automotive-Primer-Spray-Paint-2081830/100169179

11) 400 grit wet and dry sand paper - http://www.homedepot.com/p/3M-3-2-3-in-x-9-in-Imperial-Wetordry-400-Grit-Silicon-Carbide-Sandpaper-10-Sheets-Pack-5920-18-CC/202563279?keyword=400+wet++dry

12) Painters tape - http://www.homedepot.com/p/Intertape-Polymer-Group-0-94-in-x-60-yds-ProMask-Blue-Designer-Painter-s-Tape-99556/204512499

 

 

Other

1)  Novus Polish #2 - http://www.amazon.com/NOVUS-PC-20-Plastic-Scratch-Remover/dp/B002UD0GGS/ref=sr_1_1?ie=UTF8&qid=1453300408&sr=8-1&keywords=novus+polish+2

 

Tools

1) Dremel with plastic cutting bit and sanding wheel

2) Exacto knife

3) Sewing Machine

 

Assembly:

 

Forearm Mount assembly

 

1. Using a dremel with plastic cutting bit or other, cut a 1/8" x 1-3/8" rectangular hole at the indents. The indent are located at each end of the curved sections.

 

 

Clean up any burs. 

 

2. Measure, cut and install neophrene foam with adhesive. 

 

 

3. Measure and cut elastic and nylon webbing. 

 

I used a strong but soft elastic for the forearm armor section and nylon webbing for the handle section.

 

As for the elastic measurement feed one end of the elastic through one of the holes, around the back and out the other hole. Place your forearm on the mount and wrap the elastic around the forearm. Do not overlap the elastic. When ready to assemble the overlapping the velcro is where your tension will come from. You can glue this area also if you don't want to sew it, it's up to you.

 

Soft side - Towards the armor

 

 

Rough side - Away from armor

 

Pre-cut

 

 

After-cut

 

 

4. Measure and cut nylon webbing. 

 

Feed webbing through foam grip. Note: If you choose to purchase the grips I suggested you'll have to remove the plastic insert, easy to do though. Continue to feed webbing through one hole, around the back and out through the other. This time over lap the material about 1-1/2". Check tension of grip by installing your hand (with TFA glove). 

 

  

 

 

5. Sewing in velcro.

 

Start by cutting two 2-1/2" x 1" hook and loop sections of velcro. NOTE: I had plenty of 2" width velcro lying around so it worked out perfect.

 

 

   

6. Sew in velcro.

 

 

 

7. Install straps and check fitment.

 

 

 

Main body Shield assembly

 

8. Start by tracing out the sight window base return edge that will be removed.

 

 

 

9. Using dremel with cutting wheel or other remove section. Note: I found it best to leave a little bit of return edge to secure the plexiglas.

 

 

 

Next comes the paint however, before painting I took a few minutes to clean and polish the plastic for a couple reasons 1. I wanted to get an idea of what the shine will look like so I knew what style of paint to use and 2. save me the hassle of doing it later having to mindful of the painted section. Just preference.

 

10. Cleaning, buffing

 

Before buffing

 

 

 

After...

 

 

WOW! cleaned up pretty good.

 

11. Shield paint

 

Taped off area to be painted and paper to seal off the remainder of the shield.

 

 

 

12. Before painting used a little bit of 400 grit to scuff up the surface. I like using wet and dry. A bit of water get everywhere but quickly dries.

 

 

 

After....

 

 

 

13. Ready for primer. Using light grey or other spray paint area.

 

 

 

13b. After 2+ coats of primer and drying use the 400 grit again to remove any imperfections in the primer.

 

14. Paint black. 2+ coats 

 

after...

 

 

 

Let dry

 

To be cont...

[dak[TK]]

nice work

[ukswrath[Staff]]

Battle/Riot Shield assembly cont....

 

15. Install plexiglas window.

 

Remove protective layer from plexiglas. Lay shield on its face. Apply E6000 around he cut return edge. Center and place plexiglas on shield. Place something of weight on the glass. Note: If you missed any areas with glue you can always reapply later as there's enough of a gap between the sides of the glass and shield to add more. 

 

 

 

Securing forearm mount to shield 

 

In my build I decided to velcro the forearm mount to the shield instead of snaps, glue or other that semi affixes the mount. My reasoning is options. With velcro I can move the plate around for a better feel or if my left arm gets tired I can flip it over and use my right arm. Again, just preference.

 

16. Start placing the mount on the shield approximately where you think it will feel most comfortable. Mark the location.

 

 

 

17. Cut two velcro sections 4-1/4" or so x 1". Remove the backing and place on mount and shield.

 

 

 

Check fitment.

 

 

 

Reversed for when I want to switch arms

 

 

 

to be cont.....

[The5thHorseman[501st]]

Do you think it's possible to heat the sides of the shield in order to bend them like they should? Right now it appears to be flat if I'm not mistaken.

[ukswrath[Staff]]

Battle/Riot Shield assembly cont....

 

Shield tip paint and installation

Note: I'm not exactly sure how the tips are to be painted being there are very few pictures of the movie used shield that are clear enough to distinguish exactly how specific components look. In my opinion this all just best guess.

 

18. Trim any excess burs from tips. Using 400grit sand paper or scotch brite pad rough up tip area.  

 

 

 

Using painter's tape or other (ran out of painters so I used gaffers). Tape off area that will NOT be painted.

Note: Being the tips were already a good looking black I elected to only paint in the silver areas.

 

 

 

19. Primer the exposed areas.

 

 

Let dry.

 

20. Paint silver (no additional prep work performed)

 

 

Let dry

 

21. Remove tape

 

 

 

22. Apply E6000 to base of tips and place on shield.

Note: I placed the tip outer edge at the shield front crease with the corner butted against the return edge. I don't know, seems logical I guess.

 

 

 

Let dry.

 

FINISHED!

 

[ukswrath[Staff]]

Do you think it's possible to heat the sides of the shield in order to bend them like they should? Right now it appears to be flat if I'm not mistaken.

 

 

 

Yea I though about that also Germain, just not exactly sure how to go about it without warping everything around it. It may be possible by cutting a notch out of the return edge nearest the crease, force the plastic back, hold it in place then add a cover strip over the newly created gap. Just a thought.

[ukswrath[Staff]]

nice work

 

Thanks Angela

[sandtrooper[501st]]

Traitor!

 

I wish I lived next to Tony so I could steal, borrow, admire all of his wonderful toys.  Great job as always!

[ukswrath[Staff]]

Traitor!

 

I wish I lived next to Tony so I could steal, borrow, admire all of his wonderful toys.  Great job as always!

 

haha thanks my friend

[justjoseph63[Staff]]

Here it is... yet another reason to get the FO kit when it comes out.  You guys have the best toys!  Great job buddy, great job indeed.

[ukswrath[Staff]]

Here it is... yet another reason to get the FO kit when it comes out.  You guys have the best toys!  Great job buddy, great job indeed.

 

Thanks Joseph, the checkered flag is out my brother. Waiting for you at the finish line    

[Sly11[Admin]]

I demand to see you fully kitted up with shield on arm! ............please.

 

 

Sent from my iPad using Tapatalk

[TK-Sonic[TK]]

Nice touch on adding velcro to the back plate for adjustment or strap replacement.<br><br>

The greeblie tips look good.

[ukswrath[Staff]]

I demand to see you fully kitted up with shield on arm! ............please.

 

 

Sent from my iPad using Tapatalk

 

In time my fellow DO 

[ukswrath[Staff]]

Nice touch on adding velcro to the back plate for adjustment or strap replacement.<br><br>

The greeblie tips look good.

 

Thanks Rob

[Daetrin[Admin]]

Gorgeous! Well done

[ukswrath[Staff]]

Gorgeous! Well done

 

Thanks Paul 

[Mutter]

Tony, I've been following this amazing build thread when assembling mine this past week. Also studying TFA for details and noticed the forearm mount is black with white webbing. Any thoughts of updating to be more screen accurate?

 

[ukswrath[Staff]]

Hey Greg sorry for the delay. I could easily do that, just remove and paint it and add wider velcro. I'll look into it.

[flametrooper]

Great job Tony, spectacular!

[ukswrath[Staff]]

Great job Tony, spectacular!

 

Thank you