Haribon72

Here's my tutorial on repairing my thighs using model clay. In this case, I had to add shims to my thighs. Before picture: Shims added weeks ago. I had noticeable gaps and lines traveling down the thighs (you can see them well here). I ran out of shims so I had to order more from Trooperbay (notice the off-white color).

My white elastic bands holding the shoulder straps.

My flexing latex hand plates and rubber gloves (both from Trooperbay).

No return edges on the forearms

Side views

Using the heat gun, I re-shaped the kidney plate, cod, back, and abdomen to give it a tighter look around my mid-section. It looks a lot better now.

Here are the correct shoulder bells now. I spent the last week re-configuring the bells, biceps, and forearms. I had so many "armor pinch" areas and needed to redo the black straps that hold everything together. Now I can move my arms freely = taking my helmet off, holding the blaster comfortably, and putting on my gloves by myself.

Looking great Greg!

Whoooppsss! Hahhaha... I will fix that tonight. Thank you Germain!

Okay..... here's my first test fit with everything on including the gloves, TD, blaster, and the newly finished Hero helmet. Please excuse the blue tape on the kidney and abs as well as the missing 20mm strips on the back of the thighs. I know I have to work on the fitting and forming to my body shape. I feel like a linebacker now.

Here's the final look for the new belt configuration

I upgraded my belt holder (Thanks to Diana and Kyle for their ideas). I picked up Uncle Mike's Law Enforcement belt from Amazon. This belt works so well if you're a big trooper like me. My wife created and sewn the new thigh holders from scratch. My cousin Jojo recommended that they be velcro on the adjustment side to the belt. This new configuration worked out so well.

Congrats!!!

AWESOME!!! Thank you for sharing the wiring line diagrams. I was wondering how you did it.

Great work Tony! Someday I need to see your armor in person. Also, I need to ask details about the hot water bucket technique.

Thank you Germain! I removed the return edges last night. No more armor bites! This week goals: 1. Finish the thighs. 2. Finish the "clam shell" assembly (chest, abs, kidney, butt). 3. Re-work the biceps to the shoulder bells and forearms.

Another question about return edges on the chest plate, abs, back, kidney, and cod. - Can you advise on my return edges? - Did I leave too much? - Do I trim them down again? - Or should I cut them all off?

Question: How many tube stripes does the Hero helmet have? The FISD photo reference shows 13 . . . The Star Wars Costumes book by Brandon Alinger shows 12 stripes . . .

Finished Hero frown

Thank you Diana! If I wasn't working this weekend, i'd be packing up the armor and drive down tomorrow morning.

Hhahahhah!!!! The thighs and COD hate me!!! I'm about to go "HEAT GUN" on them this weekend!!!!

9. Take your time sanding to the finish frown. I sanded for about an hour. 10. You're done! Now you're ready to paint the Hero frown (in my case I just need to paint the tips again). I hope my quick tutorial with help fellow builders. Good Luck! Feel free to ask me for help.

8. Now its time to sand it out to get that smooth finish. I used plumbers sanding mesh cloth and my small filing set (both can be purchased from your local hardwood store).

7. Keep ironing side to side. And if you have to ....start ironing up and down (the idea is to mold to this final look).

4. Start to iron the bubble flat. Shape and mold the frown area as flat as you can. I used the side-to-side motion. Iron slowly. 5. Don't worry if you see rigids and gets messy (or ugly). We will sand the area later. 6. I thought about using a soldering iron, but it gets too hot and will melt a hole on the ABS. I did a test piece before. So never use a soldering iron.