CoatHanger

Ok. I’ve done some things. The thigh shims really bummed me out. I ended up buying/trying the Apoxie Sculpt. After a few trials with errors, finally sanded down to this— Then, some Rustoleum Gloss White— I still need to do some light wet sanding to make the paint smooth, but I am very happy with the results! So, as I have worked on everything else, I decided to do a “pantsless” dry run. I am pretty stoked. Obviously still things I need to work on (especially add in thighs). Any and all tweaks appreciated. Specific question—How much should I cut off the back of shoulder straps? And here is me cheesing it up. Let me tell you, HUGE grin under that frown!! Sent from my iPhone using Tapatalk

Ok, I’m currently trying to search out how you did this. Having shim issues. (See above.) Sent from my iPhone using Tapatalk

“Emergency” Shim Help. (Obviously not really, I’ll go to bed and deal with it tomorrow.) My shins turned out perfect size with all my fancy geometry. But now making them blend in is going terrible. http://i.imgur.com/KTBCxNO.jpg I added ABS paste. After entirely too much hand sanding and ibuprofen, my husband let me in on the secret that we have an electric “mouse” sander. Finally getting all the bumps of ABS off. But lots of issues— On the left thigh, I can feel the ABS of the original armor is getting dangerously thin. And I can still see the joint. (I realize those pits probably would be fixed with more ABS paste but I don’t want to put any more acetone on this thin area.) On the right, again with the pitting, and you can definitely see the joint line. Ideas?! The best I have (but not bold enough to do it without advice) is Bondo the upper “V” area bilaterally to give a smooth contour, and feather it out. I know it will have to be painted, but honestly the shim was different ABS and was going to have to be painted anyway. Help! Sent from my iPhone using Tapatalk

I had held off painting/glueing that smaller ab button plate because I had a gut feeling it wasn’t right. This reference photo is exactly what I needed! Thank you! Sent from my iPhone using Tapatalk

And back to shimming the thighs. I did some fitting. The challenges--- I need more width at the top of the thighs, but actually need to taper it at the bottom. I want the seams to be in the middle as much as possible. So, this is the line I got from the sizing: The red line is the original measurement side. The green lines are splitting the difference of the "taper" portion in order to keep the seam in the midline. A close up of the higher order geometry I had to do to figure out how to make this work: How I felt trying to figure this out: I cut all the angles and made another inner cover strip to fit behind the "new" joint. Tons of blue tape and clamps and prayer later--- Holy smokes, it actually looks decent! Whew!! Now to ABS paste! Oh... And do the other side!

Belt work! Okay, first I measured out the middle/center of the cloth belt, and lined that up with the armor belt. Then marked my holes. (Can you notice my shameful mistake? Ugh... I'll talk about it later.) Next, I used ye olde soldering iron to create the holes in the canvas belt. It took a punch through and a wiggle in order to make the hole big enough for my chicago screw. Next, I used the paint stick method to mold the belt. I hate that I can't remember who's build I found this on to give credit, but its an excellent way to make sure things bend at the boxes and not just curving the flat part between (that's what happened when I initially water bathed my thigh ammo pack and had to salvage.) Next, attaching with chicago screws. This is when I learned 1) if you measured with flat plastic and try to attach curved plastic, you will freak out when the holes don't line up. Solution-- flatten the plastic to pop the screw in; and 2) 5/32" isn't a large enough hole for chicago screw, I had to expand it. This is also where you can glaringly see my mistake. My armor corners don't line up with my belt. Ugh. I had to walk away from it and my frustration that I did that somehow. I'll fix it though, promise. I closed my drop boxes with two small pieces of velcro, because I wasn't sure if I would want somehow make these "functional" in the future. I would love to have a place to put my trunk key, so I can then keep car keys in my trunk. I also velcroed the elastic for now. It'll let me make changes if needed when I decide to make these functional. Getting close!! I know the "typical" way to attach the belt to the armor is snaps, but has anyone used velcro? I feel like Velcro is the answer when you are being indecisive about something, and that's how I feel about the belt right now. Follow up question, if anyone has ever put E6000 on their canvas belt, when you go to pull it off does it leave any type of "scar" on canvas? Just curious.

Oh! I'm stealing this! (Or more appropriately, saving it.) Was thinking my smaller plate was too big.. Thanks!

Making strapping! First I used this ABS template (1"x2", with holes drilled 10mm from edge) to mark my nylon strapping. (This is what I did at work on my lunch break!) Then I marked one end of 2" elastic pieces with the same templates (to ensure that snaps will line up). After further review, I am likely going to make more of the elastic bits and make them longer. Next, soldering the edges and holes in the nylon. I made another template and drilled some holes in my 2x4 to make it fool proof that I was putting the hole in the correct place. For the elastic bits, I folded over the last inch and soldered the holes "doubled up", so that I can have that extra strength on the elastic connections. And then, using that fancy snap press machine!! So easy! And quick! And the snaps come out perfect each time. And it makes me happy having a magenta piece of equipment in the garage. I'm still working on my thigh shim too. So far, I have butt joined the shim to one half of the thigh. Tonight I'll do final sizing and cut the shim to the appropriate taper to butt join it to the other side. Thankfully I don't need to shim the bottom at the knee. That fits fine. Then, I'll put some ABS past on the seams, sand the heck out of it, and then decide how best to deal with the color difference (unfortunately I didn't have any scraps of my armor wide/long enough for my shim, so this is made out of spare ABS). Then, lastly, will put a "fake" 20mm coverstrip straight down the middle. Or at least that's my plan unless someone has a better way! Looking like a really ugly 50mm back cover strip here: But this is what it will sort of look like after sizing.

Last update today, I swear, but I got up at 0530... I updated the holster strips to natural leather. (Holster is from AP) And, with the blaster-- (HyperFirm B-Grade)

The more I stare at it, the more I agree. I'm trying to decide exactly how/where. Do I trim along the original cod line (red line) and hide all "flare out" under the belt? Easier option. Or do I build up that seam to make it equal to the "flare out" and make it more gradual (blue line)? More time intensive option.

Another update! First, thigh ammo pack-- I used a method I saw on here to curve it using trimmed paint sticks and a heat gun. I'm happy with the result, albeit not perfect. Next, shin work-- I used ALL the clamps (minus what my husband is using currently) to E6000 on my back (LEFT) outer cover strip. (You can't see it, but I write notes to myself all over my armor in pencil-- for example, the shin had "glue outer strip" on the lateral/outer side, and has "glue hook velcro" on the medial/inner side. This is my way of TRYING to decrease errors made in haste or exhaustion.) This is the front of my right shin. Is that outer cover strip too long at top? I swear I measured twice... It looks like I might have a slow(ish) day at work tomorrow, so I have come up with a portable template to start making my nylon snap plates. I'll use this ABS template to mark the size/hole on my black nylon with a paint pen, and then can solder the holes and burn the edges tonight (don't think it'd be smiled upon if I set up a full workshop in my office). Oh, and building is always better with wine. And once that's done, I get to play with this new toy! Gold Star Press Machine with Ring Snap Dye for Line 24/15m! (See @Cricket this is why I have no more supplies budget )

Yeah, it's apparently a special problem for us shorties! Thanks though!

No advice. Just wanted to say this is awesome!

Okay, for all you "cod slicers". What do I do with this extra? I worry about just cutting it all off and changing the contour of the hip/lower ab, but I also know this double seam isn't right... Now back to sanding............

Oh! What a great idea! At this point I only have one more hole to drill, and my "supplies" budget is shot and then some, so I'll stick with my new found drill skills for now!

In my mind, it was so I could sand it all down and make it look seamless. But now, 3 hours of elbow grease later, I am questioning my logic.

Just wanted to share a bit of my research, for anyone else who either doesn't use a drill very often or is in general nervous about drilling their armor, OR both!. I can not guarantee the correctness of all this, but this is what I have found in build threads. Drill Bit Sizes for the Various Holes Split Rivets (Left ab/kidney) -- 1/8" Chicago Screws (Belt to canvas) -- 5/32" Snaps (Butt snaps, Right Floating snap) -- 5/32" Pop Rivets (drop boxes) -- 3/16" Double Cap Rivets (Thigh Ammo Pack) -- ?? I haven't found this one yet. Feel free to comment, and I'll update! Hope this helps someone else!

I'm building a AP ANH too, so gonna follow you along! I might be a touch farther along, but I've been chipping away for over a year, so there's a solid chance you'll finish first. (So maybe you can tackle that sniper knee and post how you made it work!) I love my HyperFirm B grade, but it's a StormTrooper Blaster that I get to play with, so I may be easy to please. I plasti-dipped my helmet. I like the dark look, harder to see your face in it. The hardest part is plugging the holes well enough so it doesn't seep onto the outside paint. (It was easy enough to remove for me, because I plasti-dipped before painting the frown, but I could see how that could be a PITA.)

Still at it. Sanded down my small bits. These look okay?

Thanks! I'm starting to feel like I can see the submission finish line!

Ahh. Saturday. The perfect day to be covered in ABS.... First, the morning coffee test fit--- Oh man, I'm starting to look like a stormtrooper. (Sorry the pics are all off. Obviously I left this job to someone else, who was satisfied with off center, poorly lit pictures.) Bucket is done. I trimmed the neck of the chest and I think I like where it hits. I've trimmed the ab/kidney to the proper size. I am running into some kidney notch issues. I need to research to see what I should do. Maybe I cut too much off the kidney (but was worried about throwing off the ab height if I cut more than 2" off it), because now I'm not sure how I'll make a kidney notch work. There is the option of trimming down the butt, but I honestly think it is the appropriate size for my rear end. Ugh. After this, (not pictured), I attached the shoulder straps to the chest. I water bathed the butt to help eliminate saggy diaper syndrome. Next, some reconstructive surgery. Used ABS paste to start the process of reconnecting my cod to my ab. Lessons--- 1) Start with a small amount of ABS chips. An entire baby food jar full is too much. Messes will be made. 2) It took longer for the chips to dissolved than I expected. Due to Mississippi humidity, I'm probably going to give this more than the usual 5 hours of curing time before I start sanding and re-applying. Next, forearms. How's the trimming look? Oh and I started shimming my thighs.... Let's not talk about it.

Quick question— what size hole do you drill for the 1/4” chicago screw on the belt? (Tapatalk no longer recognizing me as an FISD member so searching from my phone has become a PITA.)

Big weekend! Started setting some snaps. Have put the female (flat backed) end in some 1” nylon strips. Now those are attached and curing on my shoulder bells and biceps. Went loosely by the BillHag diagram. Oh, and added elastic. Oh, and first time with the heat gun! I made my bicep clips. They are not perfect. And one day I may try to re-do them. But I’m proud of myself and learned lots in my efforts! I (think I) finished my bucket! Well, you know “TK finished” (meaning I still may tweak it 1000x for comfort.) My fans from ukswrath are ordered (woohoo on that Memorial sale!), and are on the way. So it looks like I’ll be starting that tweaking soon. And first official bucket selfie—- And re-finished that thermal detonator. This time with the control panel on correctly. But, this is still on my “not perfect” list, and will re-do to higher level standards. And (no pictures), did my first hot water bath. I molded my shoulder pieces and my ammo pack. I think I may tweak the ammo pack, but that will be another post with dedicated pictures. But a picture of why I am so amazingly thankful for the ultimate sacrifice paid by so many for our freedom. Sent from my iPhone using Tapatalk

Oh this is good to know. Gonna write this down in my Build Notebook of Tips and Tricks. Sent from my iPhone using Tapatalk

AAAANNNDDD... I put my TD control panel on upside down. {{insert expletive here}}. E6000 for the win. Again. Sent from my iPhone using Tapatalk