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Ruthar's First Order Stormtrooper Build

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Thanks, guys! :)

32 minutes ago, Justin96039 said:

Great work! Want to build mine next?

It's definitely fun enough that I'd do it again! Maybe a bit of a break after this one, though. :P

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Final Details

 

Vinyl Decals

 

With the painting now out of the way and the armour dry, it's time to move into the final few detail components before strapping. Up first are the vinyl decals. I didn't see any decals available for the KB Props kit specifically (you can find decals for the Anovos and Jim Tripon's FOTK's on Trooperbay), so I just cut out my own. I bought a roll of adhesive vinyl at the craft store and started cutting away.

 

38941866332_a8e5aa840a_k.jpg

Untitled by Taylor Goodson, on Flickr

 

The following is the list of decals that I came up with after a lot of tedious measuring:

  • Thermal Detonator
    • 6 5/8" x 1 5/8" rectangle for the large rear rectangular section
    • two 2" circles for the end caps
  • Forearms
    • two 7/8" squares for the front forearm boxes
    • two 1 7/8" x 1/8" elongated ovals for the top underside detail
    • four 1/2" x 5/16" rectangles with angled sides for the upper backs of forearms
    • two 1" x 1/8" elongated ovals for the front top edge detail
    • two 3/4" x 1/8" rectangles for the front "coin slot" detail
  • 1 3/4" circle for the back plate circle
  • two 3/4" x 1/8" elongated ovals for the handplates
  • 3/8" square for ab box #3
  • 7/8" x 1/8" for ab box #6

When I have some time during the holidays, I'll probably put all these into a vinyl cutter and stamp out some sheets if anyone else is interested. But, for the time being, at least this list will get you by!

 

Here's what they look like installed:

 

38978362881_7f3e1f5057_z.jpg

by Taylor Goodson, on Flickr

 

25107262428_344c9702db_b.jpgUntitled by Taylor Goodson, on Flickr

 

38262503724_bd86b6611d_b.jpg

Untitled by Taylor Goodson, on Flickr

 

Gaffer's Tape

 

Along with the vinyl decals, there are some details that need to be put on with black gaffer's tape.

 

1) The end of the thermal detonator cap that sticks out should house a 3/4" band of gaffer's tape. Simply loop it around the base of the protruding cap with the seam hidden in the back.

 

38284591484_cf463f275e_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38964051072_a698c21a32_k.jpg

Untitled by Taylor Goodson, on Flickr

 

2) The slots in the biceps and the shins need to be backed with some gaffer's tape. Tear off some lengths of the tape long enough to cover the holes from the inside.

 

24113771887_39c6227eaa_k.jpg

Untitled by Taylor Goodson, on Flickr

 

3) Then, in the center of each of these strips, place a smaller strip of gaffer's tape with the black side facing up.

 

24158990117_72886a05a0_k.jpg

Untitled by Taylor Goodson, on Flickr

 

4) Then, stick the larger square face-down inside the armour with the smaller black square filling the cut out entirely.

 

24113771627_b90c7fad44_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38941866152_baa726586b_k.jpg

Untitled by Taylor Goodson, on Flickr

 

5) Do this for the biceps, both shins, and the center chest cut out.

 

38941865012_60c7824160_b.jpg

Untitled by Taylor Goodson, on Flickr

 

6) For the pill holes on the chest, we need to add a strip of mesh for accuracy. You can get an order of the perfect fabric from @ukswrath- he has a sales thread for it right over here. Thanks for sending that over so quickly, Tony!

 

39023177631_e2992fd01d_k.jpg

Untitled by Taylor Goodson, on Flickr

 

7) To install, we are going to use the same technique with the gaffer's tape, but this time we will use a larger outside strip to accommodate both the smaller gaffer's tape strip as well as the pill hole mesh. Then, just tape it down against the set of holes just like all the others.

 

39023152951_5782bb8b6f_k.jpg

Untitled by Taylor Goodson, on Flickr

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Final Details

 

Belt Finishing Touches

 

1) Now that the paint is done, it's time to affix the right side hanging boxes. JAFO's belt comes with two lengths of elastic and a pair of nylon plates. Poke two holes through the first/outer rubber layer of the belt and slip the elastic through both the belt and the nylon then back through.

 

38113861235_968fdbc37b_k.jpg

Untitled by Taylor Goodson, on Flickr

 

2) Using a good dose of super glue, glue the nylon plates down against the boxes to hold them in place.

 

27223110319_46152d3207_k.jpg

Untitled by Taylor Goodson, on Flickr

 

3) On the inside of the belt (between the first and second layers), firmly tie the elastic down with a double knot (or whatever kind of strong knot you prefer!).

 

38964055082_8b97dc5290_k.jpg

Untitled by Taylor Goodson, on Flickr

 

4) Install matching velcro to hold the plastic panel to the larger rear pouch.

 

38964055092_6129b72f0f_k.jpg

Untitled by Taylor Goodson, on Flickr

 

5) Firmly press it against the pouch and in place.

 

25129933278_68f86e5dab_k.jpg

Untitled by Taylor Goodson, on Flickr

 

6) Time to glue down the faces of the front boxes. If you have a little wiggle room, I would recommend installing a shim to get the faces to fit more tightly.

 

27223109369_582a2bb024_k.jpg

Untitled by Taylor Goodson, on Flickr

 

7) Run some super glue between the edges and push the box faces down tightly for a good seal.

 

27223109149_ec652ffe65_k.jpg

Untitled by Taylor Goodson, on Flickr

 

8) Install the faceplate to the second, large box. A good spread of super glue will do the trick.

 

25129932108_033c98ccf1_k.jpg

Untitled by Taylor Goodson, on Flickr

 

9) Center the faceplate against the box and press it down firmly and hold for a little while as the super glue sets.

 

38113862905_cc963e9f74_k.jpg

Untitled by Taylor Goodson, on Flickr

 

10) All the belt components are now complete!

 

38113862825_13a87b6b27_k.jpg

Untitled by Taylor Goodson, on Flickr

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Strapping

 

Handplates

 

Now it's time for the last part of the build - strapping everything to fit the wearer. First up is the easiest part - the handplates.

 

1) Install a large square of velcro into the backs of the handplates. The gloves I got from Stormtrooper Undersuit already had velcro sewn into the backs of the gloves to match.

 

25129931728_0a595fff97_k.jpg

Untitled by Taylor Goodson, on Flickr

 

2) Simply press the plates against the matching velcro on the gloves themselves.

 

25129931158_7b8e2cd3eb_k.jpg

Untitled by Taylor Goodson, on Flickr

 

3) According to the CRL, the vinyl decal should line up with the forefinger, so make sure that is positioned correctly.

 

25129930258_7315484e29_k.jpg

Untitled by Taylor Goodson, on Flickr

 

4) The finished pair.

 

27223106419_5ab0ba18ca_k.jpg

Untitled by Taylor Goodson, on Flickr

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Strapping

 

Shins

 

To close the shins, I installed a strip of industrial velcro along the inside seam.

 

1) With a bit of painter's tape, mark off where the overlap occurs on the inner piece. This shows you where to install the first layer of velcro.

 

38964051172_5bdaf9acdc_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38284591474_d8b4aee1a1_k.jpg

Untitled by Taylor Goodson, on Flickr

 

2) Install one side of the velcro on the outside of the inner piece (against the painter's tape edge).

 

38113861125_b6000cfbb3_k.jpg

Untitled by Taylor Goodson, on Flickr

 

3) On the inside of the overlapping section, install the matching sister side of the velcro.

 

27223106379_04f1328f9f_k.jpg

Untitled by Taylor Goodson, on Flickr

 

4) Test the closure to ensure that it holds the shin piece closed.

 

38964051122_8b876b3fd6_k.jpg

Untitled by Taylor Goodson, on Flickr

 

Spats

 

1) To affix the spats to the shins in a way that both keeps them in place and prevents them from scratching against the shin armour, I used two strips of velcro placed against the front edges of the spat.

 

25152313528_7071114474_k.jpg

Untitled by Taylor Goodson, on Flickr

 

2) I then lined these pieces up against the shin itself so the spat rests just below the ovular cutout at the base of the shins.

 

24158993767_7c063121bb_k.jpg

Untitled by Taylor Goodson, on Flickr

 

3) To close the spats at the sides, I installed velcro between the underside of the greeblie and the indentation across the open gap of the spat.

 

25129931928_45eac2598d_z.jpg

Untitled by Taylor Goodson, on Flickr

 

38964052852_5d3163cd4d_k.jpg

Untitled by Taylor Goodson, on Flickr

 

4) Here are the closed and installed shins and spats together:

 

25152314388_e9b5515036_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38307131664_4b7c67133a_k.jpg

Untitled by Taylor Goodson, on Flickr

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Strapping

 

Thighs and Suspension Belt

 

1) I decided to hold my thighs up the same way as I do on my OT TK - with a suspension belt. I went out and got a cheap stretchable belt at a nearby department store. Then, I used 1.5" nylon webbing to create a pair of loops to affix the thighs to the belt. (Do excuse my terrible sewing machine technique - it's a work in progress! :P )

 

27223110249_e4fc87b82e_k.jpg

Untitled by Taylor Goodson, on Flickr

 

27223110169_03d7ce2ac0_k.jpg

Untitled by Taylor Goodson, on Flickr

 

2) Create a pair of double snap plates using 1" nylon webbing.

 

25129933078_8767970cb5_k.jpg

Untitled by Taylor Goodson, on Flickr

 

3) Glue these plates into the front centers of the thighs. I found that an inch inward from the tip of the thigh's front was a great spot.

 

38113864125_ae09a6431f_k.jpg

Untitled by Taylor Goodson, on Flickr

 

4) Next, put on your undersuit as well as the suspension belt. Pull the thighs up to meet the loops. Then, use a piece of painter's tape to mark where the top of the thigh sits upon the loop. This allows you to lay the loop strap at the proper height during the next steps.

 

27245725279_32791b65a4_k.jpg

Untitled by Taylor Goodson, on Flickr

 

5) Line up the loop strap centered over the snaps with the painter's tape flush with the top edge of the thigh as we previously marked. Mark the holes for the snaps that match the snap plate and install them. Now, the belt and the loops can hold your thighs in place.

 

39023176971_3dbf3396e6_k.jpg

Untitled by Taylor Goodson, on Flickr

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Strapping

 

Abdomen

 

In order to better keep the abdomen sitting in the correct place, I decided to rig up a suspension system for it.

 

1) I used a trio of picture hangers in tandem with a set of suspenders to hold up the abdomen piece.

 

27223109319_5acf989ef4_z.jpg

Untitled by Taylor Goodson, on Flickr.

 

2) The teeth of the suspenders fit nicely into the picture hangers.

 

38964053282_3ebf50b37e_z.jpg

by Taylor Goodson, on Flickr

 

3) I glued the picture hangers against the top edge of the abdomen armour with some super glue. One at the center of the back (on the first magnet support) and two at the front equidistant from the center line.

 

24136511197_55198327e0_z.jpg

by Taylor Goodson, on Flickr

 

4) Once dry, the picture hangers and suspenders do a great job at holding everything up.

 

38284592664_91f9126ec7_z.jpg

by Taylor Goodson, on Flickr

 

5) The suspenders, however, were too long to be effective (even when tightened all the way) due to how high the abdomen must sit. So, I folded the straps up and clamped them to get the right length.

 

27245723939_aba1a22e71_z.jpg

by Taylor Goodson, on Flickr

 

6) I carefully took the suspenders off and measured the distances between the clips and the end of the "Y" (it ended up being 11" from "Y" to clips for my size).

 

38986608062_f326e7e2a7_z.jpg

by Taylor Goodson, on Flickr

 

7) Finally, I cut out the extra fabric and reattached the suspenders to the appropriate lengths.

 

[picture needed]

 

Shoulder Bells

 

1) To strap the shoulder bells, start by installing a 5" length of 1" strap with a snap that matches each snap on the aluminum shoulder panels. Each strap should run through the slotted holes on the sides of the yoke.

 

24136511227_19da405838_z.jpg

by Taylor Goodson, on Flickr

 

2) Slide the shoulder bells beneath the tabs. Mark hole locations on the straps as well as a mark on the shoulder bells to indicate where the matching snap plates need to go.

 

27245722239_eef07715fb_z.jpg

by Taylor Goodson, on Flickr

 

3) Install upward-facing snaps on the shoulder straps at the marks made in the previous step. Be sure everything is where you want it - if you use snaps, you won't be able to slide the straps out of the yoke slots without cutting the straps.

 

25152280238_6ba990ec44_z.jpg

by Taylor Goodson, on Flickr

 

4) Install four 1" snap plates into the shoulder bells. I use just a bit of super glue for this and let the glue set for a few minutes. Once the plates are in, snap them to the straps and you're good to go.

 

24158992017_c160b9069a_z.jpg

by Taylor Goodson, on Flickr

 

27245725909_94857bd821_z.jpg

by Taylor Goodson, on Flickr

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Strapping

 

Cod

 

To strap the cod, I filled in the two notches at the front bottom of the abdomen plate with some elastic, installed some snaps, and let the cod hang with the ability to move around a bit.

 

1) Cut out a 4" length of 2" elastic. Then, mark off 1" on each side. At 1/2" from each corner, punch a hole in the elastic. Also, create two 1" x 2" ABS plates, round off the corners, and drill out holes that match up with those punched in the elastic.

 

27245699319_9cf4376560_z.jpg

by Taylor Goodson, on Flickr

 

2) Use the ABS plates to create holes in the abdomen plate. Line up the edges of the plates with the open edges of the abdomen cut outs, then drill the matching holes.

 

27245724979_06a893707f_z.jpg

by Taylor Goodson, on Flickr

 

3) In the center of the elastic, install a rear-facing snap. Then, using rivets, install the pieces together in the following order: rivet head, abdomen plastic, elastic, ABS plate.

 

38136722155_2b34295513_z.jpg

by Taylor Goodson, on Flickr

 

4) Using a rivet gun, punch down the rivets to hold everything tightly together.

 

25152294128_e548b71894_z.jpg

by Taylor Goodson, on Flickr

 

25152314888_5912a542c6_z.jpg

by Taylor Goodson, on Flickr

 

5) Install a pair of 1" nylon snap plates on the cod piece that match up with the snaps in the elastic sections.

 

25152313558_95f15d1ae7_z.jpg

by Taylor Goodson, on Flickr

 

6) Snap the cod piece in and you're ready to go.

 

38136690235_e6aa36fc48_z.jpg

by Taylor Goodson, on Flickr

 

Posterior

 

The posterior plate will be attached to the bottom edge of the kidney section using a pair of 3" elastic strips and snaps.

 

1) Install four snaps through the posterior armour through the holes previously drilled during the assembly process.

 

24158989837_210c8b1e78_z.jpg

by Taylor Goodson, on Flickr

 

39023177861_1c2f2f26b1_z.jpg

by Taylor Goodson, on Flickr

 

2) Cut out two 5" lengths of 3" elastic.

 

27245724439_4a4a7010df_z.jpg

by Taylor Goodson, on Flickr

 

3) Install matching snaps along the lower edges of the two 5" lengths of elastic.

 

27245724039_b5831d95c4_z.jpg

by Taylor Goodson, on Flickr

 

4) Finally, install four 1" nylon snap plates into the lower edge of the kidney armour that match with four additional snaps at the top edge of the 5" elastic strips. These eight snaps will join the posterior to the bottom of the kidney section.

 

24158989947_b3430a300c_z.jpg

by Taylor Goodson, on Flickr

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Strapping

 

Gaskets

 

Installing the gaskets is very simple. The marvelous gaskets I received have a 1" strip of velcro at the top and bottom of every piece, so all I did was install a matching strip of 1" velcro into the edges of the armour to hold them in place.

 

38307163884_90d170b78f_z.jpg

by Taylor Goodson, on Flickr 

 

24158991997_cf539cf6ea_z.jpg

by Taylor Goodson, on Flickr

 

25152280318_99c77c3f28_z.jpg

by Taylor Goodson, on Flickr

 

Knee Plates

 

To strap the knee plates to the gaskets, I used Tony's method from his TFA Anovos build thread.

 

1) Cut out two strips of scrap ABS. I round off the corners to keep the edges from snagging on the gasket material.

 

24158990037_c1ba88099f_z.jpg

by Taylor Goodson, on Flickr

 

2) Using a heat gun, bend the plastic into the same shape as the interior of the knee plates.

 

27245725309_632f57f9f8_z.jpg

by Taylor Goodson, on Flickr

 

3) Drill a pair of holes into the ABS plates wide enough to receive chicago screws. Then, make a mark on the gaskets that line up with the pair of holes in the plastic.

 

38307162314_56d9b2c128_z.jpg

by Taylor Goodson, on Flickr

 

4) Install the ABS plates through the gaskets with washers and chicago screws. I used a trio of washers between every layer to try to not allow the screws to tear through the gasket material.

 

38986567922_6c93993e83_z.jpg

by Taylor Goodson, on Flickr

 

5) Install a piece of industrial velcro onto the surface of the ABS plates.

 

25152315038_b7e5fd1d9f_z.jpg

by Taylor Goodson, on Flickr

 

6) Press the knee plate against the velcro to hold it in place.

 

38307161934_945534546f_z.jpg

by Taylor Goodson, on Flickr

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Strapping

 

Chest-Back-Yoke Connection

 

To connect the chest, back, and yoke sections, I just used a couple strips of industrial velcro.

 

1) Inside the chest plate, install 1" strips of velcro at the sides of the bottom of the chest plate. At the very top of the chest plate, install a pair of triangular cuts of velcro as well.

 

38307163664_92d8289038_z.jpg

by Taylor Goodson, on Flickr

 

2) The triangular cuts at the top of the chest plate line up with triangular cuts of matching velcro upon the yoke section.

 

38136722315_1a0a27b5b7_z.jpg

by Taylor Goodson, on Flickr

 

3) Here's a picture of how the yoke and chest velcro works - I pulled the pieces slightly apart so you can see how things line up.

 

24158963627_a18fa583f7_z.jpg

by Taylor Goodson, on Flickr

 

4) On top of the lower outside edge of the back plate, there is a 1" strip of velcro that matches the inside strip of the chest plate.

 

39023152931_90acab6485_z.jpg

by Taylor Goodson, on Flickr

 

Abdomen to Belt Snaps

 

Finally, the last thing to do is install a few more snaps to get the belt to sit properly.

 

1) Glue a pair of 1" nylon snap plates just outside of the rivets on either side of the cod connection elastic.

 

38986607802_5f4cbf2b16_z.jpg

by Taylor Goodson, on Flickr

 

2) Through the innermost layer of the belt (just the nylon layer), stamp in a pair of snaps that line up with the snap plates you just installed.

 

38986611822_dbe02ec215_z.jpg by Taylor Goodson, on Flickr

 

The rest of the belt should sit tight enough that no additional snaps are needed. The back of the belt should sit snuggly atop the upper edge of the posterior plate, so no snaps or velcro are needed there (as long as your belt was measured tightly enough against the abdomen/kidney armour earlier in the build). If not, feel free to add another few snaps or some velcro along the lower edge of the abdomen armour - no one will see anything beneath the belt, so you have a bit of freedom in attachment technique.

 

With that, we are done with the necessary strapping. Now to suit up for the full complement of pictures!

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Submission Photos

 

With all the building and strapping now complete, it's time to kit up for some photos! Big thanks to my garrison mate Sean for helping out with the iPhone photography!

 

38986647302_ef3b2858c6_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38307199304_cf950ab6cf_k.jpg

Untitled by Taylor Goodson, on Flickr

 

39023197881_33efbb3e20_k.jpg

Untitled by Taylor Goodson, on Flickr

 

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Untitled by Taylor Goodson, on Flickr

 

39023198761_29f67e94f1_k.jpg

Untitled by Taylor Goodson, on Flickr

 

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Untitled by Taylor Goodson, on Flickr

 

27245751909_84052c1e3b_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38986653072_d34ab3db0a_k.jpg

Untitled by Taylor Goodson, on Flickr

 

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Untitled by Taylor Goodson, on Flickr

 

39023199581_7e70375d2f_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38136752075_6e764a4d7c_k.jpg

Untitled by Taylor Goodson, on Flickr

 

27245755749_a8cedef2b1_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38307197404_55bffdbd41_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38307194434_62c005bd7f_k.jpg

Untitled by Taylor Goodson, on Flickr

 

25152337678_e9f29aec2e_z.jpg

Untitled by Taylor Goodson, on Flickr

 

38307202334_3f32fd7b2c_k.jpg

Untitled by Taylor Goodson, on Flickr

 

27245754309_82d8722305_k.jpg

Untitled by Taylor Goodson, on Flickr

 

27245753269_2b54e44678_k.jpg

Untitled by Taylor Goodson, on Flickr

 

39023200241_7fb4eba870_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38986650942_8d85ae8fe5_k.jpg

Untitled by Taylor Goodson, on Flickr

 

38136752795_b8df1b448b_k.jpg

Untitled by Taylor Goodson, on Flickr

 

24159037847_cba2d06217_k.jpg

Untitled by Taylor Goodson, on Flickr

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15 minutes ago, ukswrath said:

Nice work Taylor :th_AnimatedBravoSmiley:

Thank you, Tony! Your Anovos TFA thread was a huge help!! And thanks for sending the pill hole fabric so quickly, too! :)

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20 minutes ago, Ruthar said:

Thank you, Tony! Your Anovos TFA thread was a huge help!! And thanks for sending the pill hole fabric so quickly, too! :)

Glad to be of assistance Taylor, thank you for the kind words.

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Very happy to say that the TFA TK ensemble has been approved! :)

 

Making a few final adjustments this afternoon (which I'll post up soon) and then heading out for a weekend of The Last Jedi events. Enjoy the film, everyone!

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Thanks so much, guys! :)

 

First outing was a lot of fun. Got a nice shot with the boss:

 

38201918955_4d401551e8_k.jpg

 

And managed a really neat picture that I like a lot - the three generations of troopers!

 

38201919015_ee3785d61b_k.jpg

Edited by Ruthar
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On 12/15/2017 at 12:43 PM, Ruthar said:

Very happy to say that the TFA TK ensemble has been approved! :)

 

Making a few final adjustments this afternoon (which I'll post up soon) and then heading out for a weekend of The Last Jedi events. Enjoy the film, everyone!

Congratulations Taylor!!!  Well done indeed! 

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1 hour ago, First0rder said:

Congratulations Taylor!!!  Well done indeed! 

Thanks, Andrew! :)

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You sir are an inspiration! I'm working on a KB kit myself and will be using this for reference going forward.  

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