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sskunky's guide to trimming and assembling CFO ROTJ armour and helmets.


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Hi Guys and Gals........

 

I thought it about time I put together a guide on how to trim and assemble the armour and helmets I offer.

 

I get asked numerous times about this and thought it would be easy if I could direct them here......

 

I will update with further information and photos as I go.

 

First up how the armour should look once it's trimmed.... I will add a few tutorials on how I trim the armour and helmets and what tools I use etc, etc..........

 

For now it's what it looks like trimmed......

 

CO2 Detail

 

IMG_2872_zpsa996479f.jpg

IMG_2871_zps5e573953.jpg

IMG_2870_zps71c68fd0.jpg

 

End Caps

 

IMG_2844_zpsc35b648c.jpg

IMG_2843_zps2ebf426c.jpg

IMG_2842_zps782d7a51.jpg

 

Sniper Plate

 

IMG_2869_zps5a242a5d.jpg

IMG_2868_zps1b2a2b91.jpg

IMG_2867_zps3cf0f23b.jpg

IMG_2866_zpsa545bcca.jpg

IMG_2865_zpsf6aee755.jpg

 

Knee Ammo Pak

 

IMG_2823_zpsa8018243.jpg

IMG_2822_zps3ef9b58b.jpg

IMG_2821_zpsd8663661.jpg

 

Shoulder Straps

 

IMG_2861_zpsc50ffc6c.jpgIMG_2864_zpsaa2b2b07.jpg

 

Hand Guards

 

IMG_2832_zps2d7a0aaa.jpgIMG_2833_zps6aed04e5.jpgIMG_2834_zps4f8ded7b.jpg

 

Drop Boxes

 

IMG_2828_zpsbbc55627.jpgIMG_2835_zps00f391af.jpg

IMG_2830_zps75ac4bd3.jpg

IMG_2829_zpsab899f6f.jpg

 

Belt

 

IMG_2858_zps77a57348.jpg

IMG_2859_zpsa74b4d80.jpg

IMG_2860_zps9d0a5901.jpg

 

Shoulder Bells

 

IMG_2841_zpsb539289d.jpg

IMG_2839_zps81572dcc.jpg

 

Forearms

 

IMG_2848_zpsa8013fa1.jpg

IMG_2847_zpsc1d9964a.jpg

IMG_2846_zpse268e97e.jpg

IMG_2845_zps8692e6f2.jpg

 

Biceps

 

IMG_2838_zps35b73402.jpg

IMG_2837_zps86a2adf5.jpg

IMG_2827_zps3718ae11.jpg

IMG_2826_zpse7e393e8.jpg

IMG_2825_zpsea08b444.jpg

IMG_2824_zps790ea745.jpg

 

Shins

 

IMG_2855_zps0b99e18b.jpg

df2880c4-4c1a-413f-98f0-82433af6b608_zps

IMG_2856_zps4eeecb4c.jpg

 

Thighs 

 

563ec7d2-e1d0-4831-a6c8-dfa21277f43e_zps

IMG_2851_zps7068d86b.jpg

83a233dc-3b86-46ff-a4ec-28cae875c9ce_zps

a1f5e226-77f5-4cc8-ba90-91ef6b772530_zpsIMG_2854_zps33e2b376.jpg

 

Back Plate

 

IMG_2820_zps4f610ff0.jpg

IMG_2819_zpsd8090a14.jpg

 

Chest Plate

 

IMG_2818_zps10fa0e9b.jpg

IMG_2817_zpseb71833e.jpg

 

Ab Plate

 

IMG_2814_zps69535a37.jpg

IMG_2815_zps4a71a785.jpgIMG_2816_zps606384c2.jpg

IMG_2813_zpsa31f142b.jpg

 

Butt Plate

 

IMG_2811_zps74c6ebc5.jpg

IMG_2812_zps249e720b.jpg

 

 

As you can see there is little to no return edge to most of the armour. I put a small edge on the leg parts and a couple of the smaller parts but that's about it.

 

You will also notice I pay little attention to dead straight cuts as I feel you get a better look if it's not perfect. There is so much asymmetry going on I feel it would look wrong perfect. The originals were thrown together and so are mine! :laugh1:

 

I will add more as I go.......... :salute:

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I said I'd do a tutorial on belt assembly. So here it is.
First sew the Velcro on the belt then lay it out.

 

 

IMG_0418_zps0869ff07.jpg


Trim about 10mm off each end of the abs belt part and drill the holes centrally at the ends.
IMG_0456_zpsb58ad492.jpg
IMG_0455_zps68c7f795.jpg

Lay that on the belt in the middle and mark the holes.

IMG_0459_zpsd853e6e6.jpg
IMG_0458_zps91229d3f.jpg
IMG_0457_zps788eb0ee.jpg

Then cut the white elastic for the drop boxes and lay them down on the belt and mark the holes.

IMG_0460_zpsbc3783e3.jpg


Glue the white elastic to the drop boxes.

IMG_0464_zpsefee3dac.jpg
IMG_0461_zpsef0657f5.jpg


Take the abs belt part and clamp it to the ab plate and drill the holes to attach everything.


IMG_0468_zps03516c30.jpg


With a hole punch, cut the holes in the fabric belt part and the white drop box elastic.

IMG_0466_zps3cfbc4e1.jpg

IMG_0465_zps6fc3832c.jpg

Make sure everything lines up and all work is good....
IMG_0471_zpsbf3a275e.jpg
IMG_0472_zpsba2f7496.jpg


Then with a couple of rivets and washers thread the rivets through the abs belt, elastic, and fabric belt and the ab plate. Put a washer on the back and secure

IMG_0474_zps1e84d30c.jpg
IMG_0475_zpsf126bb27.jpg
IMG_0476_zpse7ed678d.jpg
IMG_0477_zpsd516ca12.jpg
IMG_0478_zps34078463.jpg

.....DONE!

IMG_0479_zpsc6a2070f.jpg
IMG_0480_zps6dd7606c.jpgIMG_0481_zpsd967a964.jpg

HOPE THIS HELPS...... :salute:

Edited by sskunky
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I'm sure this will prove helpful to many.  I always love looking at CFO, so thanks on both counts.

Edited by Toddo
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  • 3 weeks later...

Thanks buddy!

 

I was hoping to get some more up but I forgot to take photos of the rest of the last build! :lol:

I'm in the middle of another but had to take this week off as I managed to put my hand through one of my windows showing the guy who surveying my property for new windows how stuck they were! Hahahahaaa

I took a small chunk out of my index finger which was a damn sight less damage than it could have been. I'd hate to think what could have happened!

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  • 1 month later...

Thanks Cedric!

I do plan on updating this thread on my next build up. I keep forgetting to get my camera out when I'm assembling. It's down to being up against it and assembling more than one at a time.

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