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HOWTO: ukswrath's FO TK (Trooperbay) Pauldron assembly with multiple rank colors

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In this thread I'll be assembling the Trooperbay FO TK pauldron.

 

I'll be installing a magnetic base, multi color magnetic vinyl sheets to represent the three colors used in the movie, foam to protect the armor from scratching and elastic to secure it to the armor.

 

Tools:

Pencil

Exacto knife

Scissors

Steel straight ruler

400 grit wet & dry sand paper or 3M scotchbrite painters scouring pad

 

Material:

Pauldron - http://www.whitearmor.net/forum/topic/34314-tfa-shoulder-pauldrons/

Vinyl Magnetic Sheet (1' x 2') - http://www.amazon.com/gp/product/B000PSL68C?psc=1&redirect=true&ref_=oh_aui_detailpage_o03_s00

Earth magnets 1/2" x 1/16" - http://www.ebay.com/itm/291593103868?_trksid=p2057872.m2749.l2649&var=590635446239&ssPageName=STRK%3AMEBIDX%3AIT

Elastic - black, 1/16" x 2', rope style - http://www.amazon.com/Dritz-9342B-Round-Elastic-16-Inch/dp/B002XNQOV6/ref=sr_1_1?ie=UTF8&qid=1453692574&sr=8-1&keywords=Dritz+9342B+Round+Cord+Elastic%2C+Black%2C+1%2F16-Inch

Neoprene foam pading 1/4" with adhesive - http://www.ebay.com/itm/CLOSED-CELL-SPONGE-RUBBER-NEOPRENE-EPDM-BLEND1-4THKX53-WIDEX12-ADHESIVE-1-SIDE-/262245444526?hash=item3d0f0bebae:g:vH4AAOSw9N1VnnGA 

Industrial Strength velcro, black 1" square 

Painters tape

E6000

Paint: 

Red spray paint - Rust-Oleum #249082 - http://www.homedepot.com/p/Rust-Oleum-Painter-s-Touch-2X-12-oz-Satin-Colonial-Red-General-Purpose-Spray-Paint-249082/100670410 

Satin Black spray paint - Rust-Oleum #265545 - http://www.homedepot...65545/203188794

Grey Primer spray paint - Rust-Oleum #2081830 - http://www.homedepot...81830/100169179

 

PPE (Personal Protective Equipment): I can't stress enough how important it is to wear PPE, especially when working with some of the tools listed above. Wear it!

Safety glasses - Hardware store

Cut resistant gloves - Hardware store

1/2 Respirator. Sanding releases small carcinogens into the air. Protect your lungs. - Hardware store or http://www.amazon.co...ailpage_o05_s00

 

Trooperbay FO TK Paudron

IMG_5682_1.jpg

 

1. Using 400 grit wet or dry sand paper remove the gloss from the plastic and prepare for primer, top portion only.

 

After..

IMG_5690.jpg

 

2. Primer spray paint top portion only. 2 to 3 coats.

 

IMG_5702.jpg

 
3. Sand primer with 400 grit. Be careful not to sand through primer.
 
4. Paint pauldron black.
 
 IMG_5715.jpg
 
If all you want is a black pauldron skip to the "lower assembly" section. If you want the ability to use multiple colors continue on.
 
When I first painted my pauldron I wanted a red one representing the FO Squad Leader. Afterwards I decided I wanted other color options. 
 
Here it is panted red. Process: Tape off 1/4" around the edge and paint.
IMG_5738.jpg
IMG_5741.jpg
IMG_5742.jpg
 
5. Installing magnets to secure magnetic vinyl sheet. Note: The magnets will secure the vinyl sheet firmly against the plastic however, if bumped hard enough it may shift.
Evenly space and glue magnets to underside of pauldron like so. Use painters tape to prevent the magnets from sliding towards each other during the drying process. I used a sharpie to first determine the location of each magnet to be glued.
 
IMG_5760.jpg
IMG_5763.jpgIMG_5764.jpg
IMG_5841.jpg
 
Lower assembly
 
6. Installing foam and elastic (upper and lower mounting) to secure it to your armor. Trace out and cut a foam section.
 
IMG_5851.jpg
 
Test fit
 
IMG_5852.jpg
 
6. Install lower mounting elastic rope as illustrated. Punch two holes in the foam in the following locations. Feed elastic through and tie together at the back (sticky) side of the foam.
 
IMG_5853.jpgIMG_5854.jpgIMG_5855.jpgIMG_5856.jpgIMG_5857.jpg
 
 
7. Install main foam section with lower elastic mounting strap.
 
IMG_5877.jpg
 
8. Install the upper mounting elastic as follows. I used separate pieces of foam in the next couple sections to secure the upper mounting elastic. Easier to access in case of repair.
 
Feed elastic through the thinner of the two sections. This one resides at the back of the armor. Tie a knot in one end of the elastic and apply E6000 to help secure it.
 
IMG_5858.jpg
IMG_5859.jpg
 
9. On the opposite side install a 1" square section of hook sided velcro in the middle of the exposed area. 
 
IMG_5865.jpg
 
10. Place foam around the remaining portion leaving the velcro exposed.
 
IMG_5866.jpg
 
11. Feed the opposite end of the elastic through the loop side of velcro. Test fit.
 
IMG_5867.jpg
 
Foam and mounting finished
 
IMG_5873.jpgIMG_5872.jpgIMG_5869.jpg
 
12. Draw out and cut two sections from the vinyl magnet sheet to cover upper section of pauldron leaving 1/4" of pauldron exposed.
 
IMG_5842.jpg
 
Cut two sections. The material already comes white which leaves me one to color black.
 
IMG_5843.jpg
 
13. Using 400grit wet or dry sand paper scuff up the white surface and prepare for paint. I will not be priming but instead I'll be using paint with primer.
 
Before, glossy
IMG_5846.jpg
 
After sanding
IMG_5847.jpg
 
After painting
IMG_5879.jpg
 
 
Finished!
IMG_5870.jpgIMG_5850.jpgbbb88233-2b40-47b0-be45-09bc06fb0b3a.jpgIMG_5875.jpgIMG_5876.jpg
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Amazed again!

 

 

Sent from my iPad using Tapatalk

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Pardon my ignorance but how do you wear it?  I do get the elastic securing the pauldron at the neck area but where does the larger loop go?  Does your arm go through the loop?  Or just the shoulder armor?  

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The only advice I has would be to move the larger loop away from the neck side about 1-2". I wants to tug on the neck side a bit. It doesn't look bad though because it actually makes the pauldron look longer than it is, which is too short according to some estimates. 

 

Here's a troop I did last weekend. 

 

12901417_10206099251305772_706746313735812472278_10206099252185794_8078548124991

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Looking through your post Tony. Looks awesome!

 

Yup I'm a lurking around here.

 

 

Sent from my iPhone using Tapatalk

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Looking through your post Tony. Looks awesome!

 

Yup I'm a lurking around here.

 

 

Sent from my iPhone using Tapatalk

 

 

Hey my friend, good to see your lurking. Hope you're doing well

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Nice job, cannot seem to find these listed on trooperbays website.<br>

Been waiting on imperial gaskets for awhile now. To get my hands on set of there gaskets and pauldron.

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