You can hold it by pressing your fingers down. You don't need a lot of force because you're not supposed to cut through he plastic. just make a scoring. Once you bend the plastic along the score line it breaks along it cleanly.
It's like how you cut glass sheets.
eFX helmets come ready to wear, so there's no messing about with them. Neither are they very accurate so they wouldn't be a good backup helmet either. Try ATA or look out for a B-grade AP helmet that the maker sells off once in a while for a discount. Both are around the $150 mark.
I don't see how a custom machined one can be cheaper than the real deal as long as you settle for a non-eagle version.
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Personally I think it just sounds like a bad idea to bother with latex plates on nomex gloves. Either use plastic plates or get rubber gloves with liners for your latex plates.
Essay? I don't know where you are getting your information from, but it's certainly not correct.
All you need is to be 18+ years of age and have a costume that meets the requirements.
Never been true at all.
Is it easier to join 501st with a different costume? Certainly. A stormtrooper is far more difficult to build than some other costumes, like a crewman. But nothing stops you from going with a TK straight off the bat.
FISD is definitely public, as you don't even need an account to read almost all of the different sections of the forum.
A public service announcment for everyone.
He also needs to rough cut all the parts out of the large sheets, cast the mic tips in resin, add and/or make other various bits and bobs and then package everything and handle the shipping.