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Ukswrath's FOTK build thread


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Well the boxes have begun to arrive. So excited






Exacto knifes (large & small)

Lexan Scissors http://www.amazon.com/Duratrax-Body-Scissors-Reamer-3-Piece/dp/B007KN0RQM/ref=sr_1_2?ie=UTF8&qid=1441204195&sr=8-2&keywords=lexan+scissors&pebp=1441204247995&perid=1E2086K8TZ8RZFFQEB6K

Optional but highly recommended: Dremel (or equivalent) http://www.amazon.com/WEN-2307-Variable-100-Piece-Accessories/dp/B00A8DXKXS/ref=sr_1_2?s=power-hand-tools&ie=UTF8&qid=1441204317&sr=1-2&keywords=dremel&pebp=1441204320209&perid=07G870JQ8R30T9MKD32X

Optional but highly recommended: Dremel plastic cutting wheel http://www.amazon.com/Gyros-46-20199-Cutter-Dremel-8-Inch/dp/B000U5ZZXC/ref=sr_1_4?ie=UTF8&qid=1441204290&sr=8-4&keywords=dremel+plastic+cutter+wheel

Optional but highly recommended: Dremel small carbide cutting bit, large and small sanding drums - http://www.amazon.com/gp/product/B002OTIZ4I?psc=1&redirect=true&ref_=oh_aui_detailpage_o08_s00

Drill with 7/32" & 3/8" drill bits

Steel ruler (large & small) http://www.homedepot.com/p/Unbranded-Cut-Resistant-Large-Gloves-7008-06/205813582

Square http://www.homedepot.com/p/Unbranded-Cut-Resistant-Large-Gloves-7008-06/205813582

40+ magnets http://www.ebay.com/itm/281363537848?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

10+ assorted clamps http://www.homedepot.com/p/OLYMPIA-Clamp-Kit-14-Piece-73-293-107/205742057



Optional but highly recommended: Belt Sander 4" x 36" - http://www.amazon.com/gp/product/B00NAXSYT8?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00

Optional but highly recommended: Hand Sander http://www.homedepot.com/p/BLACK-DECKER-Mouse-Detail-Sander-MS800B/100671602

Optional but highly recommended: Hand Sander additional 220 grit finishing sand paper http://www.homedepot.com/p/Diablo-3-7-8-in-x-5-1-2-in-220-Grit-CAT-Mouse-Detail-Sanding-Sheet-with-Hook-and-Lock-Backing-DCTCAT220H05G/202830877

Optional but highly recommended: Hand Sander additional sanding and polishing pads (kit) - http://www.homedepot.com/p/BLACK-DECKER-Mouse-Sanding-Polishing-Kit-74-580/204735220

200 & 250 grit sanding blocks http://www.homedepot.com/p/3M-Pro-Grade-Precision-4-1-2-in-x-2-1-2-in-x-1-in-220-Grit-X-Fine-

Optional: Heat Gun - http://www.amazon.com/1500-Watt-Temperature-572%C2%B0F-1112%C2%B0F/dp/B0053U2B8G/ref=sr_1_2?s=hi&ie=UTF8&qid=1442428572&sr=1-2&keywords=heat+gun

Spot putty spreader - http://www.amazon.com/gp/product/B0002JMORQ?psc=1&redirect=true&ref_=oh_aui_detailpage_o08_s01



3M Scotch Bright pad (light grey, fine grit)

Wet & Dry sand paper for final and pre-paint prep - 3M 26400PGP-4 - https://www.homedepot.com/p/3M-Pro-Grade-Precision-9-in-x-11-in-400-Grit-X-Fine-Advanced-Sanding-Sheets-4-Pack-26400PGP-4/205415931

Sanding block - http://www.homedepot.com/p/3M-2-5-8-in-x-4-3-4-in-x-1-1-4-in-Sanding-Block-9292NA-6-CC/100142732

Painter's tape http://www.homedepot.com/p/3M-ScotchBlue-1-88-in-x-60-yds-Advanced-Multi-Surface-Painter-s-Tape-with-Edge-Lock-2093EL-48N/203085525

E6000 http://www.homedepot.com/p/E6000-2-oz-Clear-Adhesive-6-Pack-237032/205382750?cm_mmc=shopping-_-googleads-_-pla-_-205382750&ci_sku=205382750&ci_gpa=pla&ci_src=17588969&gclid=Cj0KEQjwvJqvBRCL77m2-uKczsIBEiQAkx8VjKypOZN0aqqOK82w4MXdTzgcl6h3dPgSAOWUFl5vGfEaAh6C8P8HAQ&gclsrc=aw.ds

CA glue (zap a gap) http://www.ebay.com/itm/Zap-PT-01-Zap-A-Gap-Medium-CA-Glue-2-oz-ounces-NEW-Unopened-/400775409865?hash=item5d501370c9, 

Zip kicker http://www.ebay.com/itm/Pacer-Technology-Zap-PT15-Zap-Adhesives-Zip-Kicker-2-oz-/131592610768?hash=item1ea387e3d0

Plexus MA310 epoxy (old mfg Devcon Plastic welder II 14340), x3 - https://www.amazon.com/Plexus-Purpose-Strength-Adhesive-cartridge/dp/B06ZY7KMWD/ref=sr_1_1?dchild=1&keywords=Plexus+MA310&qid=1587473596&s=industrial&sr=1-1

Epoxy gun x1 - https://www.amazon.com/MixPac-DMA50-Dispensing-Adhesive-Cartridges/dp/B00KACZ8AU/ref=sr_1_2?keywords=MixPac+DMA50&qid=1562526455&s=industrial&sr=1-2 

Extra epoxy mixing tips (12 pack) - https://www.amazon.com/3M-38191-Static-Cartridges-Nozzles/dp/B00596QVHG/ref=sr_1_1?dchild=1&keywords=Mixing+Nozzle%2C+38191&qid=1587473788&s=lawn-garden&sr=8-1


Strapping (suspension system) & Connection Material:

2" wide Velcro, 3M Industrial Strength, (black), Gasket to armor connection (armor side) - http://www.homedepot.com/p/VELCRO-brand-4-ft-x-2-in-Industrial-Strength-Tape-90595/202261932.

1-1/2: wide (sew in, black) Velcro, Country Brook Design, Gasket to armor connection (gasket side) - http://www.amazon.com/Country-Brook-Design%C2%AE-Inches-Velcro%C2%AE/dp/B003KWUSV6/ref=sr_1_2?s=arts-crafts&ie=UTF8&qid=1449608909&sr=1-2&keywords=1-1%2F2%22+velcro

2" wide Velcro, 3M Industrial Strength (white), Armor to armor connection (Chest to yoke) - http://www.homedepot.com/p/VELCRO-brand-15-ft-x-2-in-Industrial-Strength-Tape-90198/202261920?MERCH=REC-_-PIPHorizontal1_rr-_-202261919-_-202261920-_-N

1" Nylon Webbing (black) - Assorted strapping (suspension) connections -  http://www.amazon.com/gp/product/B001QL2C26?psc=1&redirect=true&ref_=oh_aui_detailpage_o04_s00

2" Nylon Webbing (black) - Assorted strapping (suspension) connections - http://www.amazon.com/gp/product/B003K1HK9A?psc=1&redirect=true&ref_=oh_aui_detailpage_o02_s00

1-1/2" Elastic (black) Yoke to Shoulder Bell connection - http://www.amazon.com/gp/product/B015OPFF3C?psc=1&redirect=true&ref_=oh_aui_detailpage_o07_s00

5/8" (15mm) Elastic (black) - Left to right shoulder gasket connection - http://www.amazon.com/gp/product/B00NQ4O83W?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s03

5/8" (16mm) Nylon Ribbon (black) - Shoulder gasket connection anchor - http://www.amazon.com/gp/product/B00RQQLE60?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s00

1/2" Rigilene Boning (black), Mesh suspension (strapping) - http://www.amazon.com/gp/product/B00GBIRQJS?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s03

2" Buckle (black), Strapping (suspension) Waist belt connection) - http://www.amazon.com/gp/product/B006MKS00O?psc=1&redirect=true&ref_=oh_aui_detailpage_o07_s00

1' Buckle (black), Assorted strapping (suspension) connections - http://www.amazon.com/gp/product/B00IDBJH9I?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s01

5/8" (15mm) Buckle (black) - Left to right shoulder gasket gonnection - http://www.amazon.com/gp/product/B009X0KMV0?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s03

#24 Line Snaps, Yoke to Shoulder Bell - Tandy

12mm Double Cap Rivets (gun metal black), Shoulder gasket connection anchor - http://www.amazon.com/gp/product/B009X0KMV0?psc=1&redirect=true&ref_=oh_aui_detailpage_o09_s03

12mm Double Cap Rivets (nickle), Suspension Mesh to Ab - http://www.ebay.com/itm/121710367884?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

1" Buckle, swivel / slide release, black, strapping (suspension), chest to back - http://www.ebay.com/itm/151146077829?_trksid=p2057872.m2749.l2649&var=450215821998&ssPageName=STRK%3AMEBIDX%3AIT  

10x Chicago screws (Standard waist belt assembly) 1/4" 

1/8" x 1/4" Pop rivet, Ab to lower suspension mesh boning - 

2 spools Heavy duty nylon thread -

1 square yard mesh fabric - armor suspension (strapping) - American plastics -  

6" x 6" 1.5mm+ cover strip material - armor suspension (strapping) connection point - ATA or other


Accuracy Update Material/Hardware:

Rubber Isolation/Vibration Pad - material behind Center Waist Belt Boxes - http://www.amazon.com/gp/product/B00IT650T8?psc=1&redirect=true&ref_=oh_aui_detailpage_o07_s00

1/4" x 2" Neoprene - center layer of Waist Belt & Shoulder Plate (suspension system) - http://www.ebay.com/itm/170613703683?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Mesh - chest pill holeshttp://www.whitearmor.net/forum/topic/34176-fs-ukswraths-fo-chest-pill-box-fabric-mesh/

Gaffers tape - material behind Pill Holes - http://www.amazon.com/gp/product/B00GZE3UJ8?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00 

1/4 x 20 x 2" nylon bolts - Ab box mounting -

1/4 x 20 nylon nut - Ab box mounting -

Chicago screws (belt with 1/4" neoprene section and 1" tall center box rubber mounts) - Center belt boxes 3/4", Right side boxes 1/2", end of belt near buckle 3/8"


Pre Paint & Paint:

PPG  DFL1 Spot Putty - You local auto body supply store

3M Spot putty - https://www.amazon.com/3M-05095-Acryl-White-Putty-Tube/dp/B003P6I5KS/ref=sr_1_5?ie=UTF8&qid=1467760849&sr=8-5&keywords=Spot+Putty

Poly-Flex flexible polyester glazing putty - http://www.amazon.com/gp/product/B000P6US6A?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00

ANOVOS recommended (rattle can) - RUST-OLEUM 249090 Gloss White - http://www.homedepot...49090/202071066

Primer - Rust-Oleum 249145

Professionally Painted - Paint, Clear and Hardener - http://www.whitearmor.net/forum/topic/31877-ukswraths-tfa-build-thread-tk-10116/?p=447887



F-11D - (DIY) http://www.whitearmor.net/forum/topic/41203-f-11d-resin-kits/.

F-11D complete  - https://www.etsy.com/listing/245791161/f-11d-blaster-11-scale?ref=shop_home_active_4 

Boots & Gloves - Imperial - http://www.imperialboots.com/#

Under suit, Gloves & Neckseal - https://www.stormtrooperundersuit.com/star-wars-first-order-stormtrooper-apparel-site.html

Gaskets - Imperial gaskets - http://www.whitearmor.net/forum/topic/31019-imperial-gaskets-more-upgrades/

Gaskets - Jimmi - 

Chest pill hole fabric - http://www.whitearmor.net/forum/topic/34176-fs-ukswraths-fo-chest-pill-box-fabric-%20mesh/

Hard Hat Liner - Home depot - http://www.homedepot.com/p/3M-White-Hard-Hat-with-Pin-Lock-Adjustment-CHH-P-W12/202195392

Steel Holster kit - Available through The New Order Facebook page -https://www.facebook.com/groups/FirstOrderStormtoopers/

Pauldron - http://www.whitearmor.net/forum/topic/35470-fotk-vinyl-pauldron/ 

Cooling - http://www.whitearmor.net/forum/topic/35994-ukswraths-cooling-fan-kits/

Audio system - http://www.whitearmor.net/forum/topic/32951-interest-check-ukswraths-tfa-helmet-audio/

SHA system (hearing aid) - http://www.whitearmor.net/forum/topic/32487-ukswraths-stormtrooper-hearing-assist-system/



Cut resistant gloves http://www.homedepot.com/p/Unbranded-Cut-Resistant-Large-Gloves-7008-06/205813582

Latex gloves http://www.homedepot.com/p/KLEENGUARD-Disposable-Blue-Nitrile-Gloves-X-Large-90-Count-57374/202798509

Safety Glasses 


Important SAFETY information, PLEASE READ!!

So many chemicals that are used to assembly armor are toxic. Products like adhesives, fillers, paint, sanding byproducts, these are all toxic to your health and may cause cancer or organ damage over long periods of exposure. I can't stress enough how important it is when using these products to do so in a well ventilated area and/or wear a proper respirator. NOTE: When sanding a well ventilated area in NOT good enough, USE A RESPIRATOR suited for the job.


TFA CRLhttp://www.501st.com/databank/TK_-_First_Order


Build Chapters


Ab Boxes

Ab Boxes: final assembly
Belt pt 2

Belt Accuracy (part 1)
Belt Assembly Accuracy (part 2)

Belt Assembly Accuracy (part 3)
Biceps Accuracy (Part 1)

Biceps Accuracy (Part 2)
Chest Plate Indent Mod
Chest Plate Accuracy Mod
Chest Plate Accuracy Mod pt 2
Chest Plate Accuracy gap fill 1
Chest Plate Center and Pill Boxes
Chest Plate Accuracy gap fill 2
Chest to Yoke attachment
Forearm cont
Gaskets: thigh to shin
Greeblies (clips)
Hand Plates
Knee Caps
Paint Code
Paint prep: gap fill and sanding
Paint Prep cont
Shin Accuracy
Shin Closure
Shoulder Bells
Shoulder Bell Accuracy
Shoulder Bell Accuracy pt 2
Shoulder Bell Accuracy: gmrhodes alt
Spats pt 2
Strapping: ab to cod
Strapping: ab to posterior
Thermal Det
Thermal Det decals
Thermal Det mounting
Torso: suspension system
Torso: suspension system details
Torso: suspension system details pt 2
Torso: suspension system details pt 3
Torso: suspension system details part 4
Yoke (shoulder + back)
Yoke Re-enforcement 


501st submission pictures


Special thanks to Chris (Jancelot) for his organizational skillz

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Ok, after unpacking the NEVER ENDING levels of plastic, dang Alice and her rabbit hole, I finally began the armor trimming preparation.





Tools - 




1. Outline all the sections. I'm not going to post a pic of all the sections I traced out at the moment. If I run into something that I, and maybe others are concerned with I'll post the pic.


Chest plate.


IMG_0302.jpgIMG_0303.jpg  - 






1a. Trimming (STOP!) I need to be honest with you first. As I started the trimming I quickly realized (after 10 minutes) there's no amount of medicine that I can take to eliminate my arthritis pain and stay coherent so, as much as I'd like to say I trimmed with my scissors, in the spirit if armor building, I couldn't do it. On a positive note I have a friend, I like to call him Mr. Dremel. With a plastic cutting bit I trimmed out and sanded 6 pieces in 45 minutes. An did I say I'm in far less pain today. The Dremel is not for everyone,

but it is for me. 


NOTE: A good rule to everyone building TFAs is to NOT round off the top and bottom joining edge corners as they will need to appear seemless in some areas of the armor.


Ex. In the following picture of a thigh section (that will be illustrated in more detail later) the corners should be left square so that when it is connected and glued to the adjacent section there is a fluid seem.





Back to the trimming.








More to come...

Edited by ukswrath
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COOL!    I LOVE Dremel tools.  Everybody should have one.  My Dremel has saved me during changing out a kitchen faucet by cutting off the under sink parts that were rusted up.  


How does that cutting blade work on plastic.  I would imagine it does not melt the plastic like a cut off wheel does.




Edited by russellr2d2
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Nice work, I've got 3 dremels all plugged in with different tips, I'm just too lazy to swap tips when I'm in a building frenzy ;)

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COOL!    I LOVE Dremel tools.  Everybody should have one.  My Dremel has saved me during changing out a kitchen faucet by cutting off the under sink parts that were rusted up.  


How does that cutting blade work on plastic.  I would imagine it does not melt the plastic like a cut off wheel does.





The bit works excellent, cuts through the plastic without melting it like you mentioned. On thick plastic, especially in corners this thing is a lifesaver :duim:

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Eric, The TFA kits that you see in this area are all made by ANOVOS. They are only available to members of the 501st Legion at this time.

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How much will the Anovos TFA kits be?

At this point in time, no pricing or availability date to the public has been announced.

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  • 2 weeks later...

Have any updates?

I'm eager to hear how you got on whit the Devcon Plastic Welder II and Evercoat Poly-Flex Flexible Polyester glazing putty.



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Sorry for the delays, finishing up a fellow garrison member's armor. The glue and filler arrived this week. Hopefully next week the build will continue. 

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...After next week things should lighten up and be back at the TFA. 



Perfect! Just in time for me to start following along. Can't wait to see your progress!

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