DroidHunter

I really appreciate that advice! I realigned the brow again using four clamps just to make sure the faceplate was snug against the cap along the brow line. I also used some blue tape along the inside forehead line just to secure the whole thing. Since the left ear (again, right as you look at it) sits more flush, I aligned the indentation of the cheek tubes and taped that side down. With everything sitting as flush as possible and taped/clamped down, I used a pencil to mark the faceplate hole. I then disassembled and drilled the hole. Since the ATA kit comes with a screw assembly for the helmet, I attached the cap and faceplate with one of the assemblies and re-clamped the brow line. So far, so good. Now I just need to mark the other side the same way and I will post up some pics.

Did a little more sanding and trimming on the cap and the faceplate. As recommended, I also brought the trim of the cap back to line up better with the temple trap. The I used a few clamps to see how things lined up. I have some magnets but they weren't strong enough to pull the sides together even though they are rare earth magnets. How is this looking so far? Clearly the right side pictured above (left as you wear it) fits together pretty well. However, .... The left side pictured above (right as you wear it) does not sit together and requires quite a bit of force to hold them together. That will make drilling rather hard I suspect. Now I just need to decide where the hole in the faceplate will go to match up with the hole indicator on the cap.

Will do Keith. And thanks for chiming in on both this post and my Garrison post! At this point I'm 90% positive I will be there.

I love all of these history threads, but still can't keep any of it straight in my head. Really cool stuff though. I initially looked into buying a TK kit almost a decade ago, but couldn't finance it and eventually gave up trying. Until this year. But I still have emails from certain vendors back in 2004. I'd be curious to see which armor kit(s) I had information on from back then as the emails from don't indicate.

Thanks Steve. Its amazing how much excitement a little bit of progress can generate. It is really fascinating watching this sloooooooowwwwwlllyy transform from molded pieces to finished product -- by my own untalented hands.

Looking good!

I have followed your thread and took heed of that advice. But maybe I should shave the teeth down more. Trying to decide where to stop isn't easy -- so all advice is welcome. Here is another perspective:

How do these teeth look?

Great commercial!

Small progress. I finished the second eye. I was really nervous about working on the helmet as it is such a visible piece, but so far I am happy with the results. The eyes came out better than I had hoped. Now on to the teeth. I started the first one. Before I continue, does this look right. I have examined a hundred screen shots, but it is still hard to decide when to stop on my own bucket! I tried to stay parallel with the frown lines. Let me know if I should trim it more. I picked up a 10-piece file set that worked really well. Darn phone took blurry pics....

ATA is a solid kit. I just got mine about a month and a half ago (sadly very little work on it so far). Great kit at a really good price. The ONLY negative is that the wait list is about 8 months at present -- for the whole kit. You can usually order just a helmet ahead of time as Terrell tends to have those in stock. Good luck.

Try building one from scratch and you can make the adjustments for size as you go. ATA has helmet kits in stock usually, ready to ship for much less than you paid for a finished bucket.

For all of the Minion fans out there. This was posted over on CBM, and I couldn't resist bringing it here.

I'm sorry I can't answer your question, but I have to ask you: With a screen name of mr_speed, can I assume you are a classic KISS fan, or is there some other reason? Just curious.

I normally wear a size 9 U.S. For dress shoes, I have size 9 Rockport shoes that lace up. For sneakers, right now I own Asiacs running shoes and they are all size 9. In the TK Boots I have a pair of 9's and they fit perfectly. I can wear either thick socks or put comfort soles in them, but I can also wear them without. If anything, they run just large enough that you could get 1/2 size smaller than your normal fit, but I am quite happy with the regular 9. They also run just slightly narrow. Mine came out of the last batch TK Boots received before things really slowed down for them. Just an FYI.

That's really good advice. I wasn't sure on the angle of the trim so I wasn't sure how deep to make that cut. Like I said, easier to take off more than to take off too much. Thanks for the suggestion.

Hey brother, I saw your post and was going to forward the information I have been given, but I see you already jumped in on my thread. Good luck with the build!

Trimmed out the cap for the most part. I still need to trim away some of the excess along the bottom, but I have been cutting very conservatively based on everybody's advice. I have also left quite a bit on both the right and left side so that I don't have to worry about coming up short. Does this look like too much left behind? I also started trimming out the eyes (which I posted elsewhere so just one pic here). Slow progress is better than none...

Steve, I gave your method a shot, and I like the results. It took a while, and I only have one eye done, but I'm happy with the result. I drilled with a small bit around the ridge line perimeter, then connected the dots with an x-acto knife, and used the Dremel to clean it up. I was a little nervous the the bottom return was a little small as I drilled a little closer than I wanted in one spot, but based on pics I have looked at of finished helms, I think this is OK. Thoughts?

I like that idea too.

I appreciate the quick replies. Steve, even after watching Trooperbay's video, it did not occur to me to use the drill in this manner. I have marked the perimeter of the eye lines as Panda Trooper did in this pic (sorry, never got to take a pic of my faceplate): So you drilled all the way around the perimeter of the pencil line with a small drill bit in a manner that was perpendicular to the pencil line (i.e. as if from the top of the head and drilling down in this pic), and then connected the holes with a blade, correct? I really like that idea and will likely give it a try, Thanks for the advice! I have a small Dremel sanding post to smooth it out, just not a good cutting post for that area. Ron, I have those scissors, but I don't think I want to use them for the eyes. How did you get in there to cut in the first place?

I've read post after post on assembly, and I'm getting better at trimming stuff even though I'm still in the early stages. But I am stuck on the eyes. I was going to use a Dremel, but the wheel is big and I'm worried about the curved shape. Scissors are out. I watched the Trooperbay video. Can anybody tell me how they went about it and how it worked out for them? I don't want to mess these up!

I'll weigh in on the rookie side of this. I've been wanting to build a TK kit for years, but never thought I could afford one. But low and behold, I now have a kit ready to be assembled. Mind you, I have no experience at all, I have a crazy job and a kids at home (one less than a year old). Time is a rare commodity. And I would be lying if I didn't say that I am totally freaked out about cutting and drilling this set of unassembled armor that I have coveted since I was a child. But I have made that first cut. With my TD behind me, I have started trimming the helmet. And though I know there will be mistakes along the way, I relish the idea of being able to say "I Made this." I like the hands-on experience. I like learning something new. I'd love to troop now, but I know that it will likely take a minimum of 6 to 8 months to get through this process. Getting there seems like half of the fun. I would never fault anyone for buying ready-to-wear. I'd so the same thing if I was in the military, had to travel for work/school, etc. In my situation, I choose to build this S.O.B. and see what comes of it.

Thanks! Alright. Lots of reading and examining pics of people putting together the ATA bucket. Man, I knew the Stormtrooper helmet was wonky and non-symmetrical, but this is crazy! I had no clue until I started messing around with the pieces. Not a single aspect of this monstrosity id symmetrical. I love it. So I trimmed the faceplate somewhat conservatively, and I am about to cut the cap. Having seen all of the posts on this, I am going to cut very conservatively, especially on the right side (left as you look at it) since that seems to be the side that doesn't overlap well. Terrell already cut this one tight so I won't be trimming too much. Here are a few pics: Let me know if these look about right.

Thanks for posting this thread. Puts my mind a bit at ease as I begin trimming my ATA lid.