Knockerbot

I'm excited to be back into it. June is 10 years as a member for me. I haven't been very active the last few years but still get out here and there for troops. I started a new job that's 20 hours a week less time (now 37.5 hours per week lol) and my lead hand just told me to bring in cosplay stuff to work on during shift if I want to so I might actually have time for my hobbies now.

Alright everyone. Back after 3 years I'm getting this build rolling again. I just had no room to keep going when we moved so she got boxed up but now I've built a shop and this is my summer project for 2026. I have a few things on order from Darkside Dave. I made a choice that I regretted and chose to go back to the original idea. I sold parts not needed for a TD but now I want to make the TK more so I have a Thermal Detonator, clips, and Holster on order from Dave. For those who don't know Dave is the AM maker. So since I had stuff I needed from him anyways I just ordered new ears. The repair I did with the JB weld looked off and I don't like it. Funny enough this is the third set of ears I've messed up in the same way in the last 11 years. You can't teach an old dumb dog new tricks 😂 This time I will finally listen and not mess up my ears.

Yeah at your size the Authentic Props would fit like a dream buddy. Also AP ships from Canada as Mark is in Quebec so that may also save you some of the import taxes placed on shipments from US based builders. Not for sure but it may make a price difference going all that way south to you buddy. Good luck, keep posting.

This is my first post in years but I'd like to pitch in, I'm 6'1" and about 245lbs. The suit would fit me. I'm pretty sure you're smaller than that from the photos. My advice as someone building an AM and have previously built an AP, is sell the AM and buy an AP. Or a suit from Walt's Trooper Factory. I know it'll be a hassle but it'll be 10x easier on you than trying to make this fit.

Couldn't stand the look of it so I straightened the lenses lol

I ended up angling them because I tested it and the lenses may rest on my nose when the helmet is built so I'll just trim them later at the top to straighten them out on the inside. I'm happy with the result. I'd say the gap is about 3/32" and is pretty unnoticeable but I'm sure it'll help with fogging.

Before anyone asks, because the question is always asked, JBweld does not heat up enough to deform ABS. Maybe it would if it was thin ABS but the plastic Dave uses has no issues. I messed up on an ear and already used the weld to repair it. I'll make a post about it if it works well enough to use the ear but I'm just going to replace it if the ear looks strange after repair. I'm 99% sure it will work though.

Changed my mind on what was in this post. Thanks guys!

The posts will hold the lenses slightly out from being flush because I have found that it will keep them from fogging up if there is a little bit of airflow around them. I am doing a slightly smaller gap this time but even a larger gap wasn't noticeable from the outside on my last helmet. At the moment I'm considering just leaving the JBweld blue but I also might paint it white. I'm not too concerned how the inside of my helmet looks so I might leave it.

Installing the posts for the lenes today. I used JBweld to hold some Tposts in around the edges of the lenes. Last helmet I used 3 per lens I believe but this time I went with 2 per lens. I can add a third if it doesn't hold like I want. I've used a version of this approach last time but used Chicago screws last time but I didn't like the result with the head of the screw being too big so with the tposts the screws are 6-32 machine screws so the heads are a third of the size and will be painted black so they aren't distracting like the silver old ones were. I trimmed off half of the post so they fit closer to the edge of the the holes. I put tape on the bottoms so the JBweld doesn't go into the screwhole from the bottom and fill it up.

All I ever need to keep plowing forward is that sentence to be posted by you haha.

I am going to be doing a bit of a clean up around the holes with 600 grit sandpaper to get any remaining debris. I also traced and cut my lens today. In the past 8 years I have read so many builds and tips that I can't remember where my ideas came from or if they are actually even my ideas lol. So I traced the outline of the lens holes on paper, added 1/2 inch around the whole thing, cut the paper out, taped them to the lens and cut. I always wear cutproof gloves! I work with my hands and the last thing I can afford is a stupid injury because I slipped. Which I do often lol. Ill round them off with a rotary tool later to make them cleaner.

Alright, here I go. I secretly built a first helmet for a friend who isn't going for approval so I learned the ins and outs of this kit the last few weeks. Made a few mistakes and found a few things out that I would have missed and regretted missing on my helmet. This helmet is different from the AP helmet I built before so it was nice to have a go at it with no real consequences. Today I used a rotary tool with a sanding drum on it to clear out the teeth from behind very slowly and then used needle files from behind only to clear up the edges. Did I get the corners correct? I can never remember if they should be more rounded in the corners or not.

I have gotten my box as of Sunday. I've built the helmet twice haha. I'll do an update tomorrow

Me too buddy! Saturday!