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An amazing amount of effort going into this, I've tried a few times and always fail with big 3D parts! Allergies aside you should be wearing full PPE with most of this stuff, or you can develop them. Not sure what alternatives there are to the 2 part body filler. Maybe some thing like a resin and a filler? Would cure pretty fast too.

Getting back to this build after a couple of years off. Thigh pictures for review of top edges.

The progress is great and the helmet looks like a lot of effort was put on. You should not worry about mistakes as we all leard from them. Regarding the helmet, with a bit of fine sanding it will be ready for its final colours!! Keep going and keep updating. I have two questions: the first is "how the abs piece with the kidneys are connected? How do you wear that? Is it open in the sides while you wear it or you just squeeze in there?" The second question is " does someone know a software that can helps you fit an stl to you?" For example, i am a bigger scale trooper and now that i see your thread, i am really thinking of printing a set of R1TK trooper too but i do not know how to fit the armor on me. The thighs will be definitely small, and the abs piece should be definitely larger too. Thank you!! Looking forward to see your armor ready!!!

Please join me in congratulating Chris Pearson themaninthesuitcase as our amazing Detachment Leader for 2026! Chris will continue on leading the best detachment within the legion. He has been an absolute rock star when it comes to leading the FISD. We look forward to having another fun and successful year under your leadership!

Congratulations.

I'd love to use general automotive filler, but I'm fairly allergic to something in it... not sure if it's the filler or the hardener but it triggers Bell's Palsy and freezes up half my face... so w'ere trying to avoid that for as long as I can. But, I did invest in new respirators for my face shield so who knows, we may try again! I'm generally not a fan of fillers in general, but I knew it was part of the process if I went the 3D printed route opposed to a vacuum formed set. All part of the trials! Hoping to make some more progress before my next work trip in March.

Talk about trials and tribulations, good to see it has not deterred you. For larger seams I use automotive filler, harder to sand but it is a lot stronger, blade (spot) putty doesn't like it if it's too thick, thinner from top coats can soften the putty and it can move. We all get impatient (as I've just seen some wrinkling on something I painted this morning ) but yes definitely good drying time between coats.

Well, it’s time for another update, and I want to preface this one by saying… it hasn’t exactly gone according to plan. Honestly, at this point it’s hard to say what has gone according to plan given all the hiccups—but we press on. Last night impatience got the better of me, so with the help of some painter’s tape, my wife, and the helmet that started this whole adventure, I attempted my first partial “suit up”: Mentally, this helped more than anything. It proved the most important thing: this "idea" works—and at least these larger pieces are printing to scale (I think). I’ve been printing the legs from Mr. Paul’s files (more on that at the end), but the part I was most excited about was the helmet—and that’s been an adventure all its own. Today, I decided it was finally paint day. I stopped by AutoZone and picked up some Upol Filler Primer that I’ve seen recommended here, and I’m not exaggerating when I say it’s a game changer. Compared to my first helmet—which used strictly Rustoleum products—the Upol went on smoother, easier, and far more forgiving. Of course, what it also revealed… were all the flaws still lurking underneath. Printing errors. Rushed sanding. Impatience. You name it, I probably did it. If you’re thinking “Wow, that’s a lot of flaws” you’re absolutely right. This is what happens when you skip steps in a rush to the finish line. I basically doubled my post-processing workload because I wanted things done faster at the start (mostly to text some photos to friends and family). You can see in the photos where I marked areas for ears and brow trim placement to determine what might be passable versus what actually needed work. Spoiler: I ignored that plan and re-sanded, re-filled, and re-primed the entire helmet anyway. Why? Because this build deserves to be perfect*. [*Perfect being a "subjective" term for me] At this point, all the stages are starting to blur together — which might just be a sign I’ve been staring at this helmet too long. After more sanding, I laid down two more coats of filler primer and wet-sanded through, 320, 400 and, 800 grit. (Yes, I skipped several grits. No, I will not be taking questions at this time.) Honestly? It looked great. A few minor runs on the dome, but nothing I couldn’t sand out. I should have just stopped there. But... I got ambitious (again). Remember when I said this build deserved to be perfect? Well, apparently I lied. Mostly to myself. See them? The runs. The glorious, tragic runs. I shook the can thoroughly. I sprayed three light coats followed by one medium coat… and boom. Run city. I’m not thrilled, but it’s fine. I’m used to sanding now. Granted, sanding is coarse and rough and irritating — and it gets everywhere. Literally everywhere. (Okay, I’ll stop with the Skywalker quotes.) At this point, I’m hitting pause on this helmet to give the paint time to fully cure before touching it again. Rustoleum is notoriously finicky, and sanding too early turns it into gummy sludge that, clogs sandpaper, leaves massive globs, and sometimes I've had it peel paint clean off. So we’re hoping to avoid that scenario entirely. This is fixable. Plus, I forgot to order my 2K clear coat, so I can’t finish it yet anyway. That arrives mid-week. While the helmet cures, I’ve moved on to the new abdomen pieces. I may have gone a little heavy on the spot putty: I also just finished printing: kidney plate left thigh currently on attempt #3 for the right thigh (attempt #2 pictured) The printer actually shut itself off with 45 minutes left on a 7 ½-hour print, so I’m guessing it overheated and saved itself from a potentially worse fate? That’s it for tonight. I may have another small update tomorrow if the right thigh finally decides to cooperate. And thank you Dimitris! It's been a fun ride so far, and it's only getting better!

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