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@Chemi this should conclude all the fixed that were suggested above. Thank you @justjoseph63 for the Sugru! Belt raised Front with belt raised Back with belt raised and gaps fixed Right thigh with gap fixed in the rear Left thigh with gap fixed in the rear Left thigh with gap fixed in the front

Left forearm return edge fixed Left upper corner of belt fixed

Okay, glad that you're already aware that everything about this is a bad idea, except that it will definitely look cool... so with that being stated clearly: If you were going to go with any armor maker to do this, AM is the way to go, as they are one of the thicker and stronger kits available. Since they utilize metal molds and industrial machines when pulling their plastic, they can go a little thicker than most and still capture excellent detail. Definitely more accurate than a Rubies kit. As far as damage to the suit, if you do anything other than stand around and take photos in it, you're probably going to damage the armor. The original armor was literally thrown in the trash after stunt filming, so usually we take great care NOT to be doing the exact type of running/dodging/etc typically found in airsoft or stunt work. Be aware it is very difficult to lean, kneel, or crouch, and sitting is usually off limits as well except under certain conditions. The 'correct' chelsea boots are also not terribly comfortable and don't have good grip for running. Heck, if someone bumps into you hard enough or you fall down, you're going to have a bad time. Repairs are possible for small cracks, but a large crack could destroy a piece. I can't see this being a regular thing, but it'd be a fun $1500 gimmick for a few rounds. You'll undoubtedly want to make some mods to increase mobility (almost more akin to those Boogie Storm clowns), but I'm sure the kit could be cut to some type of compromise between some level of comfort and still looking like a stormtrooper. As far as the impact resistance... There ARE thinner spots that might not take a direct hit from close range, but in general, BBs should bounce off and be fine with some scuffs or dents at close range (there ARE still several gaps in the suit under which a thin compression suit is typically worn, so that might still hurt). The BBs aren't going to be your problem, it's going to be the terrain you're interacting with and your mobility/vision. EVA foam could be a good alternative for comfort, but wouldn't look as good. That's been done before with interesting results... So idk, there are some thoughts on that and I guess an endorsement for Dave, but yea... I would never invest the money to do this, but would love to see you do it if you're dead set! Post pics/video hahaha

I would advise against any thigh armor trimming without your shins and undersuit one to measure first. I learned this the hard way. Another tip, from someone who did it the 'wrong' way - make sure to trim for length BEFORE girth, or you'll find yourself having to shim it later. It's a cone, so if you trim... it gets narrower.

Added Velcro to the gloves The hand plates are deep so adding some padding Started forming and adding the snaps to the shoulder brackets

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.

Next up, belt work Had to trim it down a bit for it to fit through the gate of the buckle…

2nd Photoshoot, action shots. Trying super glue on the belt snap to the canvas. If this does not hold, going rivets.

And some final pics for this thread. Until I can build my blaster rack, I needed a way to display the DLT. I bought some padded tool U shaped hooks from hardware store, drilled them into conveniently spaced wall studs, and hung the DLT. I now am sourcing a good case for it so I can bring it to troops without raising eye brows in hotel lobbies...