EVA foam RO TK build

[Thrawndike bar]

Should I use Elastic for the shoulder straps?

[Thrawndike bar]

I've made a little headway in the past week.  I finished my arms and started working on strapping.

 

Here's my torso so far.  

 

And here's my abdomen.  I'm still working on attaching the belt properly.

 

 

I also added the smaller cover strips to my arms. 

 

 

And I finally started working on the helmet 

[heartstopper85[TK]]

If you didn't tell me you were working with foam I would have never known and guessed it was a fiberglass kit. Awesome job this is a fun read through!

[ThayNerd[TK]]

Looking good can’t wait to see it completed.

[wook1138[TK]]

This is very cool!  Nice work!

[Dark PWF[Staff]]

It is always fun to see what happens when one of our members gets "creative" even if it not Star Wars related.  This, though.  This is a lot of fun to follow!  Thanks for sharing, and keep at it, it is looking great!

[magni[TK]]

 

Look at you go Nerf Trooper!

[Thrawndike bar]

Thanks!  I should start posting more soon.  Work has slowed some because of the cold weather.

[Thrawndike bar]

I've just been doing whatever I can while I wait for the weather warm up and dry up.  I made one ear cap a while ago, and now I'm working on the second one.  The first one is not quite done though.  The rank bars need to be remade, plus I put them on backwards.

[gmrhodes13[Staff]]

Nice work, you have more patience than I  

[Thrawndike bar]

I made the template for the thighs!  All I need to do is get some contact cement and I'm all set.  I'm not going to make the shins until I have the boots.

[Thrawndike bar]

I got some contact cement, so I was able to make a lot of headway on my helmet!

 

Here's my ear caps.  I used hot glue for this part, so I would have a seam between it and the helmet.  It's not glued own to the faceplate in this pic by the way.  That's why it's sticking out.

 

 

And here's my "chin".   I used air dry clay on the inside of the tubes to make it look like one piece.  One side was left undone, so you could see the difference.  After it's dried, I'll sand it down.

 

 

And finally,  here's my base helmet.  Next I need to fill all the seams, then I can start doing the detail work.

[Thrawndike bar]

I felt like something was off about my helmet.  After staring at it for a long time, I noticed that my "chin" wasn't the  right size.   It's too short.  If I make a new extended piece, then I can also tilt it outward a little.

 

I'm trying to decide if I should leave it be, or make an entirely new "chin".   So wanted to ask, Is it that noticeable?  This is already my second attempt,  so I'm not keen on remaking anything.  But if It takes away too much from the costume, then it should be fixed.  I felt like I should ask you guys, because where else am I going to get a better opinion? 

[Ripper_L[Admin]]

I once tried to make a mold for vacuum pulling a helmet myself. Together with a friend I worked weeks on that mold and it would never be perfect.
It will be the same with your helmet. You need to find the level on which you're satisfied. It's impossible to get it perfectly done like an original one. So make it as good as it pleases you, nothing more.
Hope that helps

 

[Thrawndike bar]

Thank you.  You're right.  I guess I can finish the helmet.  Maybe it will look better with all the embellishments.  The chin is adhered with hot glue, so if it still bothers me, I can remove it and make another one. 

[Thrawndike bar]

I've been putting all my effort into trying to finish my helmet.  For me, seam filling is always the hardest part about foamsmithing, because it's very hard to get perfect.  I used lightweight air-dry clay and rubbed it into the seams of my helmet,  then I sanded it down and added a layer of wood glue to protect it and help it adhere.  I think my armor is going to have a bit more of a OT texture to it, unlike the R1 armor, But I'm okay with that.  I did my best.

 

Wouldn't pass centurion level if it was fiberglass, but still pretty good.

 

I also cut out the tube stripes.  I think I might have made them a little too big, but I'm still pretty happy with them.  The CRL's say between 9 and 13 tube stipes per side, so I'm good 

 

I made and painted all the greeblies separate.  I'll glue them on after I finish painting the helmet.  I left the rank bars unpainted, because I'm going to paint them after I glue them on.  The brow trim and vocoder are painted with PlastiDip to give them that rubbery look and feel.

 

The helmet is pretty much ready for it's first coat of paint.  Unfortunately It's going to be rainy and wet for the next week, so I have to wait.  While I wait, I'm just going to work on filling the seams on the rest of my armor.   I've finished making all my armor except for my shins.  I didn't want to make the shins, until I had the boots finished, so I could make sure that I'm not making them too small.  But I'm having trouble finding a cheap pair of shoes for the base 

 

Well It's coming along smoothly so far and I'm becoming more sure that I'll have it finished by the end of the summer!

Edited April 18, 2019 by Thrawndike bar

[Thrawndike bar]

I began painting the helmet this week.   I started by giving it a coat of Plastidip yesterday.  After it dried,  I filled all the gaps and open pores in the foam with Kwik seal.   

While I waited for the first coat to dry on my helmet, I gave my E-11 a few coats of Plastidip as well.

 

 

Today, I gave my helmet a few more coats.  

 

 

When my helmet is dry yo the touch,  I will fill in any more visible gaps, then go over it with a final coat of Plastidip.  I really want to just see it finished now.  It's hard to keep from skipping right to the gloss paint  But the more Plastidip I add, the sturdier and smoother the helmet will be.

 

I forgot to mention.  I fixed the problem with the chin by extending the cheek tubes and tilting the chin outward.

 

Edited April 23, 2019 by Thrawndike bar

[Thrawndike bar]

I started to work on strapping today.  I bought some nylon straps and made the belt to hold up my thighs and added the suspenders to my ab/kidney armor.

 

I was in Harbor Freight buying some EVA foam floor mats for the thicker parts of my armor,  when I ran across this pair of gloves

They were close enough to anthology gloves for me, plus they were only $5.  My only problem with them is that the leather on the fingers and palms is matte instead of shiny.

 

I made a lot of headway on the thighs.  All I have left to do on them is fill the seams and add the smaller cover strips to the front.

 

I'm 80% finished with my helmet.  On the next warm day that comes, I'll finally get to hit it with it's first coats of gloss white.  I have pretty much all the attachments for my helmet except for the lenses.  I need a tinted face shield for a Mando helmet I'm working on, so I'm considering cutting the lenses out of it.

[Thrawndike bar]

I have been doing some more spray painting on my helmet.  Though it feels like it's taking forever.   It's cloudy or raining almost every day, so opportunities to paint are few and far between.  Painting the armor should be a little easier because I'll be doing it during the summer.  I didn't realize how much patience is required for spray painting.

 

I got some primer yesterday and gave the helmet a few coats, then I sanded it down a little.  Today I was finally able to give it a few coats of gloss white. 

 

On the next sunny day I have, I'll go over it with some clear coat, then it's on to wet sanding!

Edited May 8, 2019 by Thrawndike bar

[Thrawndike bar]

The helmet is finally done!

 

 

 

 

I decided not to wet sand, so I was able to get right to adding the final details this week.  After gluing everything in place and painting the frown, I added some grime in the cracks with watered down acrylic paint.  I wanted to make it seem a little used and kind of give the traps and tears that black outline look.  

I might try some more weathering, like rubbing damp newspaper on it.  But I haven't decided yet.

 

 I painted the inside of the helmet with black PlastiDip and started adding padding and greeblies.  I'll post a pic of it when I'm finished.

 

Edited May 15, 2019 by Thrawndike bar

[Thrawndike bar]

It's been a while since I last updated this thread.  Since my last post, I've nearly completed my costume.  All I have left to do is finish up painting a couple parts of my armor and buy my boots and undersuit. 

 

I did run across one major problem during the process.  I tried to do Rogue one style abdominal armor, but the strapping system was very awkward.  You have to put it on, then put on the butt plate, rear belt half, and rear cover piece all behind your back.  I decided to make OT style ab and kidney armor.  It will be much easier to put on.  

 

 

 

I still have to sew the canvas belt and add the strapping.  I also altered my belt face to resemble the OT one.   So now my suit is made up different parts of Rogue One and ANH armor.

 

I should be able to show a completed pic of the costume soon.  Thanks!

[Thumpy~[501st]]

Great effort Caleb!

[MissionTrooper[TK]]

It's really impressive what can be done with EVA!

[Thrawndike bar]

Thanks! 

 

Did a test run today!  The pic is cut off at the waist because my boots haven't arrived yet and some of the strapping wasn't finished.

 

 

I've finished strapping up the armor since this picture was taken, so it's pretty much done!  My boots and voice amp should be arriving within the next few days, so I should have a completed photo soon!

[Sly11[Admin]]

It has been a pleasure following this build thread, you should be very proud of your work, it looks awesome.


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