DocDan's FOTK Build (Back Stage Props)

[DocDan[TK]]

My first test fit of the lower parts! Wow, feels so good to actually wear something.  I found out I needed to adjust and trim some parts on the cod, thighs and shins. Also got to see how the gaskets work so I added more foam to fill things out.  Thank goodness for my wife helping me suit up . I hope I can learn how to don this myself.

 

 

 

 

I ended up trimming more from the tops of the thighs in the front and back.  Is this looking ok?

 

 

This fine tuning the parts should help me move better and maybe dress myself.

[Sly11[Admin]]

Wow, looking good Daniel.

This looks like a very nice kit as well.

[ukswrath[Staff]]

Looking god Daniel, I know it's never easy cutting into armor that's built but I'm confident it's going to look fantastic once the mod is completed.  

[DocDan[TK]]

Thanks for the kinds words @ukswrathTony and @Sly11Andrew!

 

 

[DocDan[TK]]

Made the mods for the TD

 

Cut a notch on the top of my ab section and added a hanger on the back of the TD plate.

[DocDan[TK]]

Started the yoke section.  We had to source this from Walt’s Trooper Factory as the one that came with our kits did not have a return edge on the yoke.

 

 

 

 

make sure to remove this piece…this where the back will sit up against.

 

 

All glued

[DocDan[TK]]

The front piece is way too small for my head (or any other human) so I had to cut it a bit.  First try I used a paint can as a template…

 

Still too small of an opening, so I went to a lid from a muffin mix container(the kind schools get in bulk)…That finally did the trick!

 

 

Test fit…I made sure not to cut too wide as the chest plate will cover this.

[gmrhodes13[Staff]]

Coming along well.

 

A lot of the armor makers don't have this full piece section but it is screen accurate, can normally you can see the extra lower ridge under the chest section, the neck area shouldn't matter as the chest will cover it.

[DocDan[TK]]

Yoke and back is all glued up.

 

 

 

 

Filled seams/with Devcon

 

After first sanding…

 

[DocDan[TK]]

Chest plate up next! 

 

 

 

 

 

 

The seams came out better than I thought and are distinct!

 

 

[Sly11[Admin]]

The pulls on this kit are really crisp, I'm loving it, along with your build progress.

[DocDan[TK]]

10 hours ago, Sly11 said:

The pulls on this kit are really crisp, I'm loving it, along with your build progress.

Yeah-the chest plate, back, yoke and side belt boxes are from Walt's Trooper Factory.  The rest of the kit is Back Stage Props

[DocDan[TK]]

Slight issue, this yoke is so tight, I can’t really get it on without risking the shoulders cracking.  After thought, I decided to trim some of the front wings off(the chest plate will cover this) and extended the back wings.  This will allow me to get my shoulders in the yoke and through that space, then close it up.

 

 

Really hated to do this but I saw no other choice…

 

These wings will be removable with Velcro that I’ll install after I have the yoke on…

 

[DocDan[TK]]

 

Polyflex  time. This will smooth things out and strengthen the shoulders.  I also added more Devcon weld underneath to reinforce the seams.

[DocDan[TK]]

Second coat…

 

Had to fill small air pockets and imperfections 

sanding done and this should be final before primer

 

 

[DocDan[TK]]

Next up, belt work

 

 

 

 

 

Had to trim it down a bit for it to fit through the gate of the buckle…

 

 

 

 

[DocDan[TK]]

Doing some small items.  Made some clips for the cod and butt plate and added some elastic.

 

Epoxed some clips to the knees and will use elastic for now.  May add Velcro or a snap down the road.

 

Used some craft foam to place in the front belt boxes.  This gives the proper spacing when I put the two halves together.

 

 

 

 

[DocDan[TK]]

Added Velcro to the gloves

 

The hand plates are deep so adding some padding 

 

 

Started forming and adding the snaps to the shoulder brackets

 

 

 

 

 

[gmrhodes13[Staff]]

Foam inside the belt boxes is a great idea, always amazes me with all the builds you see that someone has a new spin on assembling a part, coming along great.

[DocDan[TK]]

Getting the markings and measurements just right before I make the bracket slots.

 

 

 

Really hated to cut into this!  Not sure if I will make slots for the 1” webbing as it will only make it weaker. Will do a test fit to make sure. I think as long as I have these tabs to keep the shoulders up and the 2 wraps on each bicep it should keep them in place. Has anyone else done this?

 

getting the fit and bends/curvature just right…

 

Gobs of e6000! Hoping this will add strength to this seemingly weak area.

 

 

[DocDan[TK]]

Opened up the vent. I was going to use a black sticker but decided to go for the more authentic look 

 

 

I used a new razor blade to make the cuts then used some force and heat to bend the flap in. I also sanded some of he edges off to make the gap a bit larger.

 

Im glad I did this. I believe I just need to use gaffers tape behind this vent.

Edited March 18, 2022 by DocDan

[TKSpartan[Staff]]

47 minutes ago, DocDan said:

Opened up the vent. I was going to use a black sticker but decided to go for the more authentic screen look 

 

 

I used a new razor blade to make the cuts then used some force and heat to bend the flap in. I also sanded some of he edges off to make the gap a bit larger.

 

Im glad I did this. I believe I just need to use gaffers tape behind this vent.

That's exactly what I did. Great job.

[DocDan[TK]]

Got the bells together and mounted with the strapping

 

 

 

 

 

I decided to make the snaps adjustable so added some Velcro. May change the 1” belting to elastic in the future.

 

 

 

 

 

[DocDan[TK]]

 

[DocDan[TK]]

Working on defining the line in the biceps as well...

 

 

I think they will look much better than the latter. I used a small micro, round file.

 

 

Adding Velcro for the shoulder and elbow gaskets