NoVATie

Interesting read.

Great job on the assembly

You have to cut both glues off, I think E6000 is easier to remove. I would use E6000. You can either buy c-clamps with long jaws or use magnets to hold the pieces closed. There are threads that list the sites that sell magnets.

I think the velcro method just attached velcro to the pull tabs on the boots and then you have a mating strip inside the calf piece. If you do it with elastic there will be some give for when you walk but the calf piece won't slide away.

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Great looking suit, well done!

That is a WONKY bucket!

The movie suits used a piece of green acetate, but a sturdier alternative is welding shield. It's the proper green but doesn't let light through so when flash photography goes off people don't see your eyes in the pictures. I don't remember the welding shield number, I want to say #5 or 6, but someone should be able to chime in with that.

Simply put - the pieces look different. Edges, shapes, and curves set the various makes apart. After you look at various images of the different kits over and over, you'll be able to pick them apart too. None of us got lay of the land overnight, it takes time and study just like anything else As for where the parts came from? Some people buy armor, then cast it to make copies. Some people sculpt armor from scratch and make their own pieces. Some people cast other people's pieces and then tweak or add their own parts to the mix.

Those electronics are really cool, nicely done!

The FX kits came with silver stickers for the thermal detonator, not sure that AP does/did.

They should be cut so that one edge slants more than the other and that's the side for your thumb. The outer edge is straight like the pinky side of your hand. At least that's how the FX plates are cut

Really cool! Looking forward to seeing it all finished.

I use a wheeled tupperware container I found at Target for about $11. Even though it has wheels on one end, it's awkward to pull it because unless you bend down really far the plastic bin drags on the ground. I just picked up a luggage cart from Walmart for about $20 and some bungee cords and that made it much easier to wheel the bin around.

Excellent work

I strap mine like the tutorial Tim posted - branched off a strap under the ribbed shoulder pieces.

I have seen a few child-sized stormtrooper costumes, but they seemed to be custom and not made-to-order. Craft foam can be an alternative for smaller troopers, though if your daughter is looking for plastic you may have to see what the makers above can do for you.

That link has been down for a while. Since you have an account here, try logging in on the MEPD with the email/password you use for FISD. Then I think you will be able to choose a display name for the MEPD.

People have also said it makes the inside look darker when you are looking in from the outside. Helps TKs keep up an imposing appearance

The pieces don't always line up perfectly and may take some "finesse-ing" to get right. I always lined up the sides that people could see the best, and the inner edges may have been less perfect. Some trimming or heat-gun work may get the edges to play nice, just take your time. The plastic does have some give so you may be able to get things to line up when you glue them, even though it doesn't seem like it just holding the pieces up.

I mounted the fans on little foam cubes to isolate them from vibration. I hot glued the foam to the fans and then hot glued to the helmet. I bought 12V computer fans (Evercool 40mm fans from NewEgg.com, the model number is EC4010M12CA, item # 35-119-049 - $2.99EA) Some people use squirrel cage style fans, and there are sellers for them here on the boards. For batteries I just wired 2 AA batteries in series with a 9V for each fan to give 12V. Little plastic battery holders I got from Radio shack are velcro'd into the helmet. I also wired a switch between the battery leads and the fans and I used a sliding switch. At some point I think I will replace them with rocker switches because it's really hard to work the slide with gloves on

There is also a how-to series on Youtube that shows construction of an FX kit. The pieces are slightly different, but in terms of prepping with the painters tape, marking and cutting the pieces, it's helpful. It's sometimes easier to see it done from A to B with video rather than see it in just pictures.

E6000 dries clear and you can cut off any excess, so I wouldn't worry about it. You can always practice gluing two pieces to get an idea of the squish/ooze of the glue so you don't use too much.

Pretty cool improvements

They ship from the UK. ------------