Tiny TK Build (3d print)

[zediyeti[TK]]

Howdy! The time has come that I figured I should make a WIP thread. I've been working on this build for a few months now, just never got around to posting anything up about it.

 

I am very short, so I didn't think there was any way I would ever be fitting a full sized kit onto myself. I've seen some other smaller people have success, but I just didn't believe it was for me. I have a FO tie pilot, and while it does fit me relatively well when all is said and done, the chest is still too big and I had to print myself scaled down forearms and shoulders. Considering how similar that armor is to the FOTK, I was and still am doubtful that I could get an ABS kit to work for me. Not that I need to justify why I'm printing a kit, I just like to overexplain.

 

I started off using these files at the suggestion of one of my GMLs: https://www.etsy.com/listing/1089257123/first-order-stormtrooper-3d-print-file?ref=yr_purchases

I did realize quickly that the shape of the belt boxes is off. They're weirdly rounded, so I instead opted to use these, which are more accurate and also a sturdier model: https://www.etsy.com/listing/1218969215/fotk-belt-boxes-3d-model-stormtrooper?ref=yr_purchases

 

Everything is printed at around 88%, making me into a 22/25 scale figure!

Prints were done by me, fuzzma, and another costuming friend. 

 

I just jumped into printing and sanding, so here's a bunch of photos with captions. There's not much to be seen other than lots of sanding and painting. I started this project at the start of August, so these are from the past few months!

 

I bought some gloves off a garrison mate, so here's a sizing test with the handplates

 

Some printed bits before I got the one piece ab printed off

 

Yay, one piece ab!

 

Got my boots, from Keep Trooping

 

Sanded and primed

 

Test fit!

 

The first version of the shins were too small to fit around the boot. I kept the height at 88% and increased the x/y to 91%

 

Sanding work, also the first time I used an electric sander. I'm not sure if I like it

 

Primed and awaiting final paint

 

Test fit!

 

Gasket test. More on making the gaskets later

 

Bunch of glossy stuff

 

Backplate/yoke sizing test

 

Comparison with my tie chest. It's not a huge difference, but every bit helps!

 

More test fits

 

Using poly filler on the seams

 

White paint comparison to ABS. It's the Behr gloss white

 

2k session! Painted some stuff while making TIE repairs

 

Yet another test fit

 

Everything printed ?

 

Most recent test fit, as of today!

 

Edited October 23, 2024 by zediyeti

[zediyeti[TK]]

Sanding, priming, sanding, painting, more sanding.... I'm nearing the end!

 

I tried out one of those plastic staplers, it was pretty nifty. I'm planning to cover the staples with some epoxy resin to lock 'em all in there.

 

Here's some FO armor partying!

 

More painting work

 

Aaand I finally sewed an arm gasket! Got the sizing all right the first time!

 

Got velcro sewn onto the gloves at last

 

Here is a painting update, which has been updated since taking this. Chest, TD, and the rest of the leg parts are painted as well

 

Some greeb printing work, done by a friend and garrisonmate

 

I believe I have everything ordered to finish this up, short of getting some velcro/clips/elastic for assembly and such. The helmet is in progress, soon!!

[dblcross[TK]]

I feel you brother! so much sanding! Your kit looks great so far!

[gmrhodes13[Staff]]

Nice work so far. The two things I hate about printing, sanding and sizing 

 

[zediyeti[TK]]

As you may notice by my forum tag being updated, this costume is done! Not really anything interesting to show by way of photos, unless you really like seeing sanding progress. But here's what I've got.

 

First things first, I finally got my helmet! Printed at 92% scale in PETG, so smaller than usual but not as small as the rest of my armor. It was a perfect fit first try, whew. And thus began many hours of sanding, priming, and painting

The brow and frown were hand painted matte, as well as the rectangle cutouts. The trapezoids were done by tracing the shape onto painters tape, then cutting it out of satin permanent vinyl. It worked great! I tried metal mesh but swapped to the printed version. Don't think I have any up close photos of that right now though

 

Took advantage of some warmer days to get stuff painted with the 2k. I'd paint outside, then rush it all to the basement with the space heater to cure. It seems to have worked out so far!

 

And I finally got down to some assembly business. There is some weird stuff in the files where there's no overlap to piece the shins/thighs together, so I had to get creative. I used strips of ABS and glued them in, the thighs are one solid piece and the shins have velcro glued to a strip of ABS that then fastens it closed with elastic on the other side to allow it to hinge. It works, I just had way too much velcro on at first. I have some other ideas and suggestions to make it work better, though. Still a work in progress to make it the easiest to wear and take off

 

The leather skirt is attached with velcro. It holds way better than you'd think it would!

 

The abdomen boxes are attached with screws and heat set inserts. The back of them is atrocious, good thing no one will ever see that outside of here

 

The belt boxes were also held on with nylon and screws to the belt. Had to do some creative engineering to figure this out, attaching the white to the black

 

Greeb painting

 

Gaskets were finished sewing with the bias tape and. velcro. No straps yet, but I got there!

 

The detonator is also held on with screws and heat set inserts. I attached a piece of folded over ABS to hook it over the abdomen, and some velcro at the bottom for extra security. I might change this setup a little though, we'll see! The black  is the smart vinyl as seen in this picture. The tube is held in place by a piece of EVA foam wedged inside at the back, works great and keeps it super in place!

 

Tests of the gaskets and arms

 

The carnage of my basement. At this point I was so close to done and just wanted it over with. So many small tasks left to do

 

Oh yeah, here's my holster. Not much to say, it's a holster cut out of plastic. It is actually functional, unlike the one provided in the files I used

 

I lined the inside of several parts with EVA foam, to protect the armor underneath them. The chest/back are EVA foam lined, as well as the underside of the shoulders. I have it done similarly on my FOTI, and decided it would not be a bad idea to bring it over to this. I also further reinforced the chest plate with epsilon pro, and abs glued to the edges of the seams to keep it from flexing too much and cracking, because it was already starting to when we took app photos. uh oh. Should be good for a while now though! Another piece that is ugly inside, and is no one's business.

 

Pulled a marathon day to finish everything up with some help, and got photos done. I have never taken app photos that look cool, so here's these.

 

First time I'd tried it all on! No test runs, full send. I'm very happy with how it turned out, and got approved on December 30! Here's some details. I did add shoulder tabs after this

 

Andd the first time I wore it out, it was 20F and I practically froze my toes off. I was joking our photos would all have motion blur from shivering, but so worth it

√

 

And yes, I can kneel. A crowning achievement moment for me

 

There's definitely upgrades and fixes I want to make, especially the visor. A bubble lens would be ideal, just have to get around to making my own buck and vac forming one most likely. Everything else is quality of life upgrades as I figure out how to wear this. But, the worst is done! The costume is troopable and approved, and looks freaking awesome. I'm very happy with it, despite the "flaws" that probably only I see.

 

Anyone who plans to 3d print a kit, I would by happy to advise on what I did for some of the quirks of the files. Feel free to message me with questions, because I definitely left out a lot on this thread. Printed armor can look good, and is surprisingly comfortable!!

[gmrhodes13[Staff]]

A whole lot of sanding there, well done.

 

Congratulations on receiving approval 

[Sly11[Admin]]

Congratulations! Lots of hard work, but it has paid off.

[JBar[TK]]

Oh wow! Congrats! What was your process to sand and polish the armor? It looks like it came out really well

[zediyeti[TK]]

1 hour ago, JBar said:

Oh wow! Congrats! What was your process to sand and polish the armor? It looks like it came out really well

I do 80 grit against the print lines, 220 with the lines, 400 against. This initial sanding gets it pretty dang smooth. Wash it with dawn, then spray with filler primer. 

Wet sand with 400-600, wash again. Another layer of filler primer, wet sand with 400-600 again, wash, then use spot putty on any spots that aren’t completely rid of lines yet. Wet sand down with 400 again, and now it should be completely smoothed. Oh and I use files and folded sandpaper to get into the grooves and such. Lots of patience

I then do regular white primer, wet sand that lightly with 600, then finally paint the gloss white. Unless I’m immediately painting the 2k on top of that the same day, I’ll do a 1000-2000 grit wet sand on the gloss before 2k. 

[Tall_Trooper[Staff]]

Looks cool!

Good work 

[themaninthesuitcase[Admin]]

I can't even think how much work that must have been!

Well done trooper!

[shashachu[TK]]

Wow, incredible work. Can't tell at all it's printed.

 

Out of curiosity, exactly how tall are you? I have been slowly slowly working on a FOTK for years, and have now been swapping some parts out for 3D printed.

[zediyeti[TK]]

On 2/2/2025 at 8:29 AM, shashachu said:

Wow, incredible work. Can't tell at all it's printed.

 

Out of curiosity, exactly how tall are you? I have been slowly slowly working on a FOTK for years, and have now been swapping some parts out for 3D printed.

Thank you! I am 5'3, 160cm. 3d printed is absolutely the way to go at this size

[shashachu[TK]]

On 2/13/2025 at 4:57 PM, zediyeti said:

Thank you! I am 5'3, 160cm. 3d printed is absolutely the way to go at this size

Same size as I am :) Is everything printed in PETG?

 

I have been trying to avoid printing the helmet but it may end up looking like a bobble head (I have the old Anovos one.)

 

Very inspirational build!

[zediyeti[TK]]

1 hour ago, shashachu said:

Same size as I am :) Is everything printed in PETG?

 

I have been trying to avoid printing the helmet but it may end up looking like a bobble head (I have the old Anovos one.)

 

Very inspirational build!

Yup, everything is PETG.

 

I’ve tried on a friend’s full size helmet with my armor…. it’s major bobble head unfortunately. It wasn’t that bad to finish the helmet, and it’s great having it fit so well!  Not as light as the abs ones of course, but it’s not too heavy especially compared to some of my resin cast helmets 

[Crim Tash]

I print the abdomen and back section.

I need to open without bending to much the abdomen to fit in, is that the same for you ? Did the paint and clear resist?

Also for the back my "shoulder" are printed and i use the metal tack too but when i put it on its breaks in part. Do you think that printed in one piece like you would help? I have to do some contorsion to put the back on.

[zediyeti[TK]]

On 2/17/2025 at 6:07 PM, Crim Tash said:

I print the abdomen and back section.

I need to open without bending to much the abdomen to fit in, is that the same for you ? Did the paint and clear resist?

Also for the back my "shoulder" are printed and i use the metal tack too but when i put it on its breaks in part. Do you think that printed in one piece like you would help? I have to do some contorsion to put the back on.

I slide into the abdomen opening without modifying it and have had no problems with it. The back is also weird to put on with how small the gap between the rams horn and the side is. you could trim the rams horn a bit. Printing in one piece is always best, when possible. or planning your print line direction and seams around how/where the item is going to flex