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teddz77

FO full Armor Pepakura build

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Hi everyone,

 

I've been wanting a FO trooper armor since I saw the movie, but paying 7 grand for the Anovos suit just isn't going to happen. Even the kit is more than I'm willing to pay for vacuum formed plastic.

 

So I found a pepakura file of the complete suit and started the measuring and scaling process. The file was originally made for someone 5'7" and I'm 6'1", so everything needed to be adjusted. It's FAR from accurate, but it's a decent base to work off of and with all the reference I accumulated, making it accurate should be relatively painless. The plans are, the suit will be white epoxy/fiberglass with rubber gaskets, mic and speaker for the helmet and custom electronics for the weapons to make them light up and go pew pew.

 

I'm still not 100% done with the scaling of the parts, but I've already managed to print out and assemble some pieces.

 

The following are just the raw paper assembly. I still need to go over them with CA (cyanoacrylate) glue (this helps in making things somewhat rigid and 'seals' the seams to keep any interaction between the glue and epoxy) then hit them with epoxy and fiberglass cloth, THEN spend more time than I care to count sanding and shaping everything. After the hard parts are done, I'm going to make a template for the gaskets and cast them, then tackle the heavy blaster and a sidearm.

 

There are a few more parts that I printed but haven't had a chance to assemble yet since I had some commissions to complete and get shipped off to clients... If all goes well, I plan to have this suit ready for the next AthensCon...

 

Shoulder

32321054361_d085ef5e7c_z.jpg

 

Bicep

32232705322_86857aa8d6_z.jpg

 

Forearm

31570347713_f7f3444664_z.jpg32381151345_e2a922e392_z.jpg

 

Hand plates

31570345563_cbd38dd09d_z.jpg

 

Knees

32442089545_53703f8224_z.jpg

 

I plan to update as I progress...

Thanks for looking... :)

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Good luck you have a lot of work ahead of you

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I'm a pep fan myself.  Are these free files or paid?  Can you post a link?  At least this may get me started while we wait for other sources for good kits.

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So...How many hundreds of hours are you going to need to spend on this...And how many hundreds of dollars in glue, resin, fiberglass cloth, Bondo...Etc.

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I absolutely love the determination and dedication mate, and by no means am I trying to discourage you in your quest.

 

I myself was prepared to do an entire kit from pepakura. Then I started to get concerned with weight, maintenance, and all the extra heat generation and overall appearance.

 

Those kits aren't as expensive anymore, and for around the same cost as what you are about to invest in doing.

 

https://www.anovos.com/collections/star-wars-the-force-awakens/products/star-wars-the-force-awakens-first-order-stormtrooper-standard-kit-pre-order

 

Super stellar work so far mate, and can't wait to see how it turns out.

 

Here to help if I can as well so don't hesitate to ask!

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Hard-core costuming, that is all. Thanks for the share.

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I'm a pep fan myself.  Are these free files or paid?  Can you post a link?  At least this may get me started while we wait for other sources for good kits.

 

I can't recall where I found them, the RPF maybe, but they were free. I can email you the original file if you like. PM me.

 

So...How many hundreds of hours are you going to need to spend on this...And how many hundreds of dollars in glue, resin, fiberglass cloth, Bondo...Etc.

 

It's not as bad as some people think. Because of the glue I use, UHU Universal contact cement, putting the together goes pretty quick. The shaping is also pretty quick because I do a lot of the roughing while the "bondo" isn't fully cured. It's like an eraser in it's cure and I use a rasp or heavy grit sand paper to take off what I need. I don't know how many hours, but I would estimate it at a few hundred spread out over the next few months. The helmet will take the most time. I already have a partially finished helmet, but it needs more work in correcting it than just making a new one that's much closer.

 

As for the cost, since I'll be making just about everything as a one-off I'm estimating around 700 euros in all build materials also including the purchase of gloves, boots, belt and under suit. To offset some of the cost, some of the parts I'm making for the blaster & pistol out of aluminum I will offer for sale.

 

Building suits, props, models and such is what I do.

 

I absolutely love the determination and dedication mate, and by no means am I trying to discourage you in your quest.

 

I myself was prepared to do an entire kit from pepakura. Then I started to get concerned with weight, maintenance, and all the extra heat generation and overall appearance.

 

Those kits aren't as expensive anymore, and for around the same cost as what you are about to invest in doing.

 

https://www.anovos.com/collections/star-wars-the-force-awakens/products/star-wars-the-force-awakens-first-order-stormtrooper-standard-kit-pre-order

 

Super stellar work so far mate, and can't wait to see how it turns out.

 

Here to help if I can as well so don't hesitate to ask!

 

Thanks for the kind words..

 

The weight doesn't really concern me that much. It's not going to be a very heavy layup process. I'm going to use epoxy and some light cloth that's used in R/C. If needed I'll reinforce some areas with adequate layers, but if it's not needed, I'll keep it light. I also don't do a "rondo" slush inside the pep. That adds a ton of weight that isn't needed. Before I lay up the epoxy and fiberglass cloth, I drench the pep in cyanoacrylate glue - Super glue. This helps seal the joints from any interaction between the contact cement and the epoxy or resin, and it also makes the pep as hard as plastic. You can still crush it, but it holds it shape very well.

 

As for the heat, if this were foam, there's a good chance I would overheat real quick. The helmet will have fans and as for the suit, maybe some cooling system for a cool shirt if it's needed. There's another suit I'm working on that I'm considering making out of foam, only because it's going to be fairly bulky and making it out of paper is just too much of a headache.

 

Meh... I'm not into buying something when I can make it. I'm that kinda person... I like the challenge of building it and figuring out how to do things. Plus, I need this ready by the next AthensCon in December.

 

Hard-core costuming, that is all. Thanks for the share.

Thanks... I have an update coming soon..

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Absolutely nothing wrong with that mate!

 

Really looking forward to watching this all come together - subscribed!

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