DocDan's FOTK Build (Back Stage Props)

**DocDan[TK]** · February 1, 2022

Everything seems to be installed now. My wife said it sounds good so I am going with that for now.

Added some tactical helmet padding not really for fir but more for sound deadening. (plus it just looks cool! )

The bucket should be done other than adding more padding but I want to see what I need after I do some troops. I customize I'm sure after some wearing time.

Planning on working on the AB section next, gluing it together and cutting out the 7 small boxes (ammo?) around the front and sides. I got some good work done on it already! Thanks for looking.

**DocDan[TK]** · February 6, 2022

Got sidetracked installing the lid. On to working on the abs section!

I had to glue the sides first.

Trimming and shaping the 7 boxes..

**DocDan[TK]** · February 6, 2022

The ab boxes are coming together. Tedious work but calming and gratifying making them fit the slight curve of the ab section.

I notice this kit keeps the vertical ridges running straight down below the boxes. The belt needs to go here. I will be cutting those ridges out and placing some small tabs in place there to make that area flush so the belt will fit under the boxes.

Next, I’ll start filling the side seams with poly flex to make that seamless. Start drilling holes through the ab section, glue nylon bolts to the boxes and mount those.

**gmrhodes13[Staff]** · February 6, 2022

They are a great little tool, for those looking for something similar you can also find them in less expensive plastic these days too

Coming along nicely

**DocDan[TK]** · February 8, 2022

Did some more of the belt boxes

These seem to be the two front belt boxes. I really wish they had a curve to them

**gmrhodes13[Staff]** · February 8, 2022

No requirement to have them curved, although if you have access to a 3D printer (or someone who has one) there are some nice files here thanks to John.

**DocDan[TK]** · February 16, 2022

It’s amazing how much gets done when you put a day into building! I got some good work done today on the ab section. I was able to mark and drill holes, cut and install the nylon bolts and fill the sides with poly flex.

Making pilot holes for the seven boxes

Used a 11/32 bit for the nylon bolts to go through. Really freaked me out drilling through this!

**DocDan[TK]** · February 16, 2022

I started on the seven boxes and installing the nylon bolts. I marked the boxes on the inside while they were taped to the ab, through the holes I drilled. This allowed me to know where to glue the bolts.

I hope this stuff holds as I have never used this before.

These will set up overnight then may attach them tomorrow.

Mixed some poly flex up to fill the side seams

Letting this set overnight then will sand out and see how it looks tomorrow.

**TKSpartan[Staff]** · February 16, 2022

great advances , keep it up ! :jc_doublethumbup:

**DocDan[TK]** · February 18, 2022

Backstage place a nice indent as to where the blaster base mounts…

I used CA glue to attach it. I believe there are screws that will go through this part and the metal base and bolt on the inside of the thigh.

**Sly11[Admin]** · February 18, 2022

Looking good so far Daniel, I'm getting the popcorn out for this as you get deeper into the build. :popcorn:

**DocDan[TK]** · February 20, 2022

On 2/18/2022 at 1:11 AM, Sly11 said:

Looking good so far Daniel, I'm getting the popcorn out for this as you get deeper into the build.

Hey thanks! I’m truly enjoying it so far!

**DocDan[TK]** · February 20, 2022

It was 53 degrees here the other day so I was able to sand outside and get a quick coat of black paint on my belt boxes.

I used 60 grit, 220 and 800

Edited February 20, 2022 by DocDan

**DocDan[TK]** · February 21, 2022

I started the process of rigging. We bought tactical vests for this project. I was not going to use it at first and go with a simple suspender type system however, I wore the vest around the house for a day (looked like John McClain for the day) and it reall is not that bad!

I installed two straps up high to suspend the ab section from.

Filed out a groove to accommodate the strapping

E6000

Edited February 21, 2022 by DocDan

**DocDan[TK]** · February 21, 2022

Needed to close up the back so used a spare piece and cut down to act as an attachment point for some Velcro

Trimmed it down a bit…

Then glued it in place on one side. I’m amazed at how it shrugged things up so much so I don’t think I need strapping in the back.

Pardon the an impolite person shot- :blink: It really feels good to actually wear something finally!

and the front…

**DocDan[TK]** · February 21, 2022

Rigged up the rest of the vest for the thighs

Test fit for strap length…

**DocDan[TK]** · February 22, 2022

Worked on the TD. Did a mock up and looks pretty good.

Starting the glueing process with CA

There was not much to glue to so I added a shim..

Next up is the add filler and sand down.

Edited February 22, 2022 by DocDan

**DocDan[TK]** · February 22, 2022

I used plasti weld for the small space on the center rib and used poly flex for the cylinder seams

**DocDan[TK]** · February 24, 2022

TD all sanded!

**DocDan[TK]** · February 25, 2022

Working on the butt plate. Tested it by using magnets on the strapping and the belt in place first.

Installed snaps on the ab section-these will be covered by the TD plate.

snaps installed on the butt plate and offset a bit for the TD plate coverage.

**TKSpartan[Staff]** · February 25, 2022

Coming along nicely Trooper. :duim:

**DocDan[TK]** · February 25, 2022

14 hours ago, TKSpartan said:

Coming along nicely Trooper.

Thanks Mario for cheering me on through this build! :icon_bow:

I am feeling the end is near! Working on the cod now, then the upper chest pieces.

Dan

**TKSpartan[Staff]** · February 25, 2022

10 minutes ago, DocDan said:

Thanks Mario for cheering me on through this build!

I am feeling the end is near! Working on the cod now, then the upper chest pieces.

Dan

I need to update my own build thread, I'm almost finish too. just final adjustments and the submission photos. :56pullhair:

**DocDan[TK]** · February 27, 2022

Working on the cod. Got it all lined up and rigged.

Used the excess belt material to use as an extension for the cod and snaps.

Installed snap on the interior of the cod.

All snapped in! The belt will cover the snaps.

All together…

**DocDan[TK]** · March 1, 2022

Got the thighs all Velcroed and gasketing fitted and rigged. I plan to do a test fit tomorrow of my lower half while I have my wife here to make adjustments and take some photos.