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Hello, I'm Jake from Starkiller Garrison in Pennsylvania. I've been in the 501st Legion for 6 years as a ROTJ TB and as a 501st ROTS CloneTrooper. Been trooping with my son whose a Rebel Fleet Trooper for a while as well. I'm almost completed on a TLJ Praetorian Guard which should be ready soon. Just ordered armor from WTF to start a ANH Hero. Ready to join the ranks of the classic Star Wars trooper. When it gets here, I'll be looking for helps from all of you.

Any pieces under any strain usually take a little longer to dry, I leave mine for 48 to 72 hours. Although they can be seen on some screen used armor you may want to trim these ends of your coverstrips as they may catch when moving your arms, this is more a comfort thing than screen accuracy

This is really cool. Would you be willing to do this for someone else as a service? Asking for a friend ;-)

Looks good! There might be a bit of return edge you could trim off to help with the fitting of the forearms - but I also found that a bit of reshaping of the forearms were needed to get a more round opening (one forearm was good, the other was not). Also, it looks like the top of the biceps have a bit of return edge - I find it more comfortable to trim that away. As for attaching everything together - it wouldn't hurt to wait until you get a feeling of how it looks with the chest piece in place.

Progress update: I have got the cover strips on the arm pieces. Had a bit of trouble with the forearm strips lifting after 24 hours of E6000 setting. I finally left them for 2 1/2 days and they are not going anywhere. the left forearm is a bit snug at the top by the elbow. I may need a hot water bath to round it slightly. I don’t think there is any extra material to trim to open up the opening. should I be attaching the biceps and forearms at this point with the elastic, or so I wait until I have the chest and shoulder pieces done to make sure the positioning is correct?

I got a little work done on both calfs this evening, bit of trimming with the shears and fitting the rear coverstrips. I'm going with the velcro closures it seems to give a secure fit.

Definitely worth the fix, looks muuuuuuuuuuuch better

Auto filler/bondo should be fine, just don't be too rough when sanding/filing. Also make sure you rough the area with some coarse sandpaper to give it something to grip too