Ashari[501st] Posted February 7, 2025 Report Posted February 7, 2025 (edited) I'm well on my way through constructing my Captain Phasma costume, but I was encouraged to share the planning and building notes I've done so far! So... here we go! I'm going to try to break out each piece into a new post to keep it a little more organized. Notes about me: From Canada, so a lot of vendors are going to be Canadian 182cm tall (just over 6'), but most of my height is in my legs - I have a short torso 93kg (about 205lbs) 1 - References 2 - Materials & Supplies 3 - Prep & Painting 4 - Assembly & Strapping 5 - Cape Build 6 - Transportation 7 - Getting Dressed Edited February 7, 2025 by Ashari 2 Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 1 - References CRL: Captain Phasma TLJ CRL Captain Phasma Costumers group on Facebook How to put on a Screen accurate Captain Phasma armor! #captainphasma - Adventures of a Stormtrooper Build Threads: Indie's TLJ Phasma Build Sea Marshall TFA Phasma Build Ukswrath FOTK Build Darth Biscuits Rogue One Build The Rascal Kings Build Captain Drydock FOTK Build (youtube) Individual Pieces Threads: Hard plastic lens attatchment help needed... General Trooping Stuff: How to DIY USB Helmet Fans USB Fan Kits Best Cosplay Voice Amplifiers for Masks/Helmets: Shidu S617 vs Norwii S368 'Mini' (youtube) DIY Sanding Box: https://www.instructables.com/DIY-Indoor-Sanding-Box/ Duralumen spray instructions: https://youtu.be/0smZWrOxGMs Chrome Paint videos Spray Paint Chrome Showdown Revell Rustoleum Duplicolor Krylon IronLak Review Scale Model How To - hpiguys Workshop Testing Revell Chrome Spray - Is It Worth $35 ?? - Barbatos Rex Testing Different Chrome Spray Paint - Barbatos Rex AK Super Chrome: My First Impressions #akinteractive #superchrome #modelcars #modelcarbuilding - Time Machines Scale Models Comparing Alclad and Duralumen Chrome Paints. - gordontarpley Will Duralumen Paint hold up to handling without a topcoat? - gordontarpley How to Paint with a Spray Paint Gun (& Air Compressor) HVLP Spray Gun Basics- How To setup - Tom Stringham How to Setup your Paint Gun to Spray a Car Guide! - Paint Society How to use a paint spray gun. Vaper HVLP gun in this video - backyardmech Cleaning an Airbrush How To: Cleaning the Airbrush - The All-In Nerd Hobby Cheating 213 - How to Clean Your Airbrush Fast - Vince Venturella Cleaning Airbrush Between Colors // Quick Tip Airbrushing - Baker Builds Edited February 19, 2025 by Ashari 1 Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 2 - Materials & Supplies Armor List Black balaclava (Koa Ski Mask Pattern) Black undersuit From Geeky Pink: Strapping harness Neck seal Gloves Shoulder gaskets Elbow gaskets Knee gaskets Shiny Shorts Boots (Feel Grounds Chelsea) Cape (See Section 5 for build) 4.5m of black cotton duck cloth 1.5" wide leather strips Amazon Black Leather Strap Strip 1.5 Inch Wide 79 Inch Liquitex Gloss Heavy Gel Medium Michaels Canada Liquitex® Gloss Heavy Gel Medium Tulip Matte Fabric Paint in Red Michaels Canada Tulip Matte Brush-On Fabric Paint Belt Trooper Bay TFA Belt Sound system: SHIDU Mini Voice Amplifier Portable Rechargeable Bluetooth Speaker https://www.amazon.ca/dp/B08HQZL6DK Armor Jimmiroquai Helmet & Visor Chest & Back Kidney Thermal det Shoulders Bicep Forearm Wrist plates Hand plates & fingers Belt boxes Cod Butt Thigh Knee Shin Foot plates Materials PPE Respirator 3M Half-face quick mask respirator Goggles Nitrile Disposable Gloves Costco Canada Nitrile Gloves Coveralls XL Disposable Coverall Assembly Materials Hot glue gun Heavy Duty Snap Pliers https://www.amazon.ca/Fasteners-【Upgraded-Version】Snap-Fastening-SewingTarps/dp/B0C532Y22F Air compressor HVLP Paint Spray Gun Airbrush Rotary Tool Needle files Precision needle files Princess Auto Curved Precision File Set E6000 CA Glue Clamps of various sizes Black Felt 1” black webbing ⅝” black snaps 2” black elastic 1” & 2” black hook & loop Black styrene or ABS strips Black Gaffers tape https://www.amazon.ca/dp/B00VVHZZQU Weather Stripping Foam Tape 2 Inch Wide X 1/4 Inch thick https://www.amazon.ca/dp/B0747DK7HW Chicago Screws https://www.amazon.ca/dp/B07CYYGWC9 Sandpaper (250, 400, 600, 800, 1000 - wet sand) Bondo Glazing spot putty tube Milliput BC Hobbies Black Milliput Tack cloths Bondo Tack Cloth Dupli-Color Grey filler auto primer https://www.canadiantire.ca/en/pdp/dupli-color-scratch-filler-auto-primer-11-oz-0471019p.html Dupli-Color Black sandable filler auto primer https://www.canadiantire.ca/en/pdp/dupli-color-sandable-auto-primer-0471012p.html Grey Plasti-dip !! CAUTION !! THIS IS A HAZARDOUS CHEMICAL 2K Clear Coat https://www.napacanada.com/en/p/MAX3680061 DURALUMEN Chrome Paint – TheDigitalArmory DURALUMEN Chrome Paint – 1 Litre Small Bits Helmet Frown Mesh Helmet Frown Fabric - Black cotton double gauze Helmet Padding - Tactical Helmet Pads https://www.amazon.ca/dp/B0C3GJ7N41 Helmet fan - DC Brushless 5v Blower style https://www.amazon.ca/dp/B07V2KVQB7 Chest Mesh - UkswrathsSpeciality FOTK Chest Mesh & Gaffers Tape Extra 3D printed greeblie clips - MrPoopie/TheRascalKing's TFA & TLJ First Order Stormtrooper Greeblie Pack Holster Ball Bearing 3mm x 7mm x 3mm https://www.amazon.ca/dp/B07FW18RQY Transportation Bin DEWALT Tough Chest 38-inch 238.5L Mobile Tool Box (HomeDepot) SunGlo Soft Foam Cushioning 18 X 18 X 3 Inches (Walmart.ca) Foam Camping Mat (this might not be for sale any more) hometrends Plush Velvet Blanket, Queen size (Walmart.ca) Random foam I had around the house from other projects Multi-Tool (RYOBI 18V ONE+ Lithium-Ion Cordless Multi-Tool) Any long bladed cutting tool (Olfa Heavy-Duty L-1 Cutter 18-mm ABS Plastic and Stainless Steel - Yellow) So much hot glue Armor Protection 3m velvet chenille with sherpa backing Fabricland Blanketing Edited February 11, 2025 by Ashari Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 3 - Prep & Paint !! CAUTION !! This kit is a fiberglass kit. Fiberglass sucks. DO NOT BREATH IT IN. If you're building the fiberglass kit, consider building a DIY Sanding Box to protect your health, as well as wearing appropriate PPE including respirator, goggles, gloves and coveralls. PREP Wash the fiberglass with soapy water - this removes any remaining release agents on the surface Sand the insides of all pieces to remove any sticky pokey bits (Sanding & plastidip photos) Give it a good vaccum Rinse the armor again to remove any left over fibers OPTIONAL: Coat inside with Plastidip This is optional because you could always coat it with something else, however you should coat with something to prevent transfer of any fiberglass to your clothes or skin Vents Cut out the vents with rotary tool Chest vent https://databank.501st.com/mw501/images/6/6e/CHEST_CROP_TLJ_PHAS.png Chest pill holes Bicep pill holes https://databank.501st.com/mw501/images/7/7a/BICEP_CROP_TLJ_PHAS.png Shin pill hole https://databank.501st.com/mw501/images/f/f6/SHIN_CROP_TLJ_PHAS.jpg Helmet frown https://databank.501st.com/mw501/images/b/b2/HELMET_CROP_TLJ_PHAS.jpg File edges of vents until smooth Add greeblie buckles with E6000 (E6000 is probably overkill, but hey, I'm learning) 2x Bicep 4x Forearm 4x Thigh 4x Shin (velcro post chrome) 2x Spat Add greeblie shin boxes (left calf only) with E6000 https://databank.501st.com/mw501/images/f/f6/SHIN_CROP_TLJ_PHAS.jpg Add holster (right thigh only) with E6000 https://databank.501st.com/mw501/images/0/03/THIGH_CROP_TLJ_PHAS.png Fill gaps around shin boxes and holster with Milliput Fill any "large" imperfections in the armor surface I used Bondo Glazing Putty for the majority of these, primarily because I learned about Milliput after I was far past this step. Wet sand with 400 sand paper PRIMER OPTIONAL: Clean surface with air from compressed air (either Compressor & Air Blow Guns or Compressed Air Duster Can) Clean surface with tack cloth to remove any left over particles Coat with a light coat of Dupli-Color Grey filler auto primer Wait about 15 minutes Coat with a medium coat of Dupli-Color Grey filler auto primer Wait for at least one hour (I left them over night, but I'm 100% learning as I do this) Wet sand with 400 sand paper Check for imperfections & do minor fills (with either Bondo or Milliput) Wait for filler to dry OPTIONAL: Clean surface with air from compressed air (either Compressor & Air Blow Guns or Compressed Air Duster Can) Clean surface with tack cloth to remove any left over particles Coat with a coat of Dupli-Color Grey filler auto primer Wet sand with 600 sand paper Check for imperfections & do minor fills (with either Bondo or Milliput) OPTIONAL: Clean surface with air from compressed air (either Compressor & Air Blow Guns or Compressed Air Duster Can) Clean surface with tack cloth to remove any left over particles Coat with a coat of Dupli-Color Grey filler auto primer Repeat this until either you're happy with the surface or you want to cry a lot PRIMER Round 2 OPTIONAL: Clean surface with air from compressed air (either Compressor & Air Blow Guns or Compressed Air Duster Can) Clean surface with tack cloth to remove any left over particles Coat with a light coat of Dupli-Color Black sandable filler auto primer Wait about 15 minutes Coat with Dupli-Color Black sandable filler auto primer Let cure at least 1 hour prior to clear coat Clear Coat !! CAUTION !! This is a hazardous material. Spraying 2-pack isocyanate paints is the main cause of occupational asthma in the UK https://www.ultrimaxstore.com/blogs/news/how-to-use-isocyanate-paints-safely-ultrimax-coatings-uk Spray Max 2K Clear Glamour Clear Coat Causes serious eye irritation. May cause drowsiness or dizziness. Suspected of causing cancer. Suspected of damaging fertility or the unborn child. May displace oxygen and cause rapid suffocation Precautionary statements (GHS) : Obtain special instructions before use. Do not handle until all safety precautions have been read and understood. Keep away from heat, hot surfaces, sparks, open flames and other ignition sources. No smoking. Do not spray on an open flame or other ignition source. Do not pierce or burn, even after use. Avoid breathing dust/fume/gas/mist/vapours/spray. Wash hands, forearms and face thoroughly after handling. Use only outdoors or in a well-ventilated area. Contaminated work clothing must not be allowed out of the workplace. Wear protective gloves/protective clothing/eye protection/face protection. If exposed or concerned: Get medical advice/attention. If on skin: Wash with plenty of water. Take off contaminated clothing and wash it before reuse. If skin irritation or rash occurs: Get medical advice/attention. If inhaled: Remove person to fresh air and keep comfortable for breathing. IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses, if present and easy to do. Continue rinsing. If eye irritation persists: Get medical advice/attention. Store in a well-ventilated place. Keep container tightly closed. Store locked up. Protect from sunlight. Do not expose to temperatures exceeding 50 °C/122 °F. Dispose of contents/container to hazardous or special waste collection point, in accordance with local, regional, national and/or international regulation. Spray pass: 2 spray passes each. 0.6 to 0.8 mil Evaporation time: 5 to 10 minutes / 20° C (68°F) Drying - Infrared appliance: 18 hrs / 20° C (68°F) or 60 mins / 60° C (140°F) IR: approx. 15 mins For best results, use the can at a temperature of 20–25°C and a relative humidity of 45–60% High humidity can cause the finish to lose gloss After allowing approximately 24 hours dry time, It may been polished by hand or machine. If possible, have this step performed by a professional with proper equipment. Shake the can vigorously for two minutes Remove the red button from the cap Turn the can upside down and attach the button to the pin on the bottom Press the red button firmly until it clicks into place Shake the can again for two minutes After activation, this product will last approximately 48 hours. Coat with a light coat of 2K catalyzed clear coat https://www.napacanada.com/en/p/MAX3680061 Wait about 5-10 minutes Coat with 2K catalyzed clear coat Check the surface Masking Thermal detonator: control panel is black. Reference: https://i.imgur.com/dHqmL0u.png, https://databank.501st.com/mw501/images/e/e4/TD_CROP_TLJ_PHAS.jpg Thermal detonator: right-hand recessed end cap is black. Forearm: Detail box includes black rectangle on small edge perpendicular and closest to wrist. https://databank.501st.com/mw501/images/4/4a/FOREARM_CROP_TLJ_PHAS.jpg Kidney: The large box has a small black recessed square on the lower left of the wearer. https://databank.501st.com/mw501/images/4/4c/ABS_CROP_TLJ_PHAS.jpg Chroming Duralumen spray instructions: https://youtu.be/0smZWrOxGMs From Lumin's Workshop: Apply using an Airbrush or HVLP touch-up gun, wearing an appropriate VOC / painting respirator. Use high pressure (~30PSI) and low paint volume (1/4 open on HVLP fluid needle or 1/18 open on airbrush). Spray approximately 8-12 inches away in fast, lightly overlapping strokes until the desired opacity and shade is achieved. It is recommended to stop every couple of passes and allow the Duralumen to dry for at least 5 minutes. Then buff with a clean microfiber cloth or blue shop towel to remove unbound dust particles and produce a high shine. Duralumen is very resistant to removal in this way. Working slowly in this method can allow you to work up to your desired shade and opacity. Leave Duralumen to cure for at least 8 hours prior to handling. If applying a clear coat, leave at least 24 hours at room temperature for full cure to retain maximum shine and reflectivity. Clear Coat Round 2 (OPTIONAL) Most people find that clear coat dulls the shine of chrome paint. You can decide whether you prefer high reflective shine or protection for your paint. That said, I'll be clear coating my finger and shoe plates because they're quite small and I find the dullness not as noticeable. Plus they will be the pieces more likely to see wear. !! CAUTION !! This is a hazardous material. If possible, have this step performed by a professional with proper equipment. Coat with 2K catalyzed clear coat https://www.napacanada.com/en/p/MAX3680061 Edited February 9, 2025 by Ashari 1 Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 4 - Assembly & Strapping Install helmet visor Install helmet frown mesh Install helmet padding Install helmet fans Install chest mesh and gaffer tape Install bicep gaffer tape Install shin gaffer tape Figure out amp mount for chest Attach felt strips along any overlaps on interior to prevent rubbing Shoulder underside Chest overlap Vest overlap Belt box backs Mid-shoe plate Spat bottom Suspenders (Geeky Pink) Suspenders to shoulder gasket by velcro Suspenders to Thighs by buckles Back & Chest Back sides by snaps and black elastic Chest to back by velcro? Magnets? Shoulders by snap straps & shoulder support 11.2mm tall at join between back and shoulder bell Arms Shoulder gasket to Bicep by velcro Bicep to Elbow Gasket by velcro Elbow Gasket to Forearm by velcro Gloves Make elastic loops for each joint piece Attach elastic via hot glue to each piece Slide onto each finger with glove on to find placement Tack elastic on each finger to secure Add hand plates by velcro Kidney Kidney closure Kidney to Butt by snaps Kidney to Cod by snaps Cod to Butt by elastic (styrene plates) Thermal Det by velcro? Belt? Sew buckle to one end Stick weather stripping to rubber Belt boxes attach Chicago screws (2x per box to keep level) Snaps to kidney Leg Holster needs metal plate, screws & bearing Thigh to Knee Gasket by velcro Knee plate to gasket by velcro Knee Gasket to Shin by velcro Shin to calf by velcro Shin clips by velcro Spat to Shin by velcro Shoe plates Toe plate by elastic string (d-ring attach similar to ?) Mid-foot plate velcro to toe plate Mid-foot plate by elastic to Shoe back plate & sole by elastic string Edited February 7, 2025 by Ashari 1 Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 5 - Cape Build Cape build discussion and photos Copy example pattern from Captain Phasma Costumers group Cape Pieces: 4x cape pieces 2x 4.5” x 9” pocket 2x 5.5” x 11.5” pocket 3x 1.5” x 14” leather strap 1x 1.5” x 16” leather strap Cape Materials: 4.5m of black cotton duck cloth 1.5" wide leather strips Amazon Black Leather Strap Strip 1.5 Inch Wide 79 Inch Liquitex Gloss Heavy Gel Medium Michaels Canada Liquitex® Gloss Heavy Gel Medium Tulip Matte Fabric Paint in Red Michaels Canada Tulip Matte Brush-On Fabric Paint Sewing Instructions Add 0.5” to all edges of cape pieces (except leather straps) for seam allowance Sew vertical seams with french seam Sew with wrong sides together at ⅜” Clip seam Press and flip seam so right sides are together Sew at ¼” Sketch bottom hem curved shape & cut (https://imgur.com/bmYZqQu) Hem bottom with double rolled ¼” hem Cut hemming piece for left and right edges Left edge: 1.5” seam, cut piece 2.5” x 230cm (½” seam allowance) Right edge: 1” seam, cut piece 2” x 125cm (½” seam allowance) Sew hemming piece to right edge ½” seam allowance Press hemming piece long edge seam allowance to inside Press to hemming piece to inside and sew with 1” seam allowance Pin leather straps to left edge & stitch into seam allowance The top strap is 1.5” x 16” and the bottom strap is 1.5” x 14” The top strap is located about 1” above the bottom strap “around the left hand area” Sew hemming piece to left edge ½” seam allowance Press to hemming piece to inside and sew with 1.5” seam allowance Pin pockets and 1x 1.5” x 14” leather strap Back left side of the cape starting approximately in the shoulder blade area Pockets in 1, 2, and 1 pattern The top and bottom pockets are approximately 4.5” x 9” 2 middle pockets are approximately 5.5” x 11.5” The bottom pocket has a black leather strap approximately 1.5” x 14” attached horizontally to the bottom left corner Sew on pockets Finish neckline Sew on 1x 1.5” x 14” leather strap at right shoulder Paint external cape surface with Liquitex Gloss Medium except left seam (https://imgur.com/KQAyJ8W) Paint external left seam with red fabric paint (https://imgur.com/MQSiOTG) Close left attachment end Add closure Determine if clip to armor needed to keep cape from choking me Edited February 11, 2025 by Ashari 2 Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 6 - Transportation Transportation Items List: Large rolling bin Perimeter padding https://imgur.com/JhW4x8a Blanket https://imgur.com/HpVpuIW Rolling Bin photos & notes https://www.whitearmor.net/forum/topic/56976-asharis-tlj-captain-phasma-build-thread/#findComment-795396 Helmet bag Chest wrap 2x Shoulder wrap 2x Bicep wrap https://imgur.com/q6v2ChT 2x Gauntlet wrap 2x Glove/hand box Kidney wrap https://imgur.com/GS4h47N Thermal det bag https://imgur.com/XhShTDq Belt storage 1x Cod wrap https://imgur.com/kzNyL99 1x Butt wrap 2x Thigh wrap https://imgur.com/gjfhpXi 2x Knee wrap 2x Shin wrap 2x Shoe wrap Mic/Amp pack Undersuit & neck seal bag Gasket bag Balaclava & shiny shorts bag Shoe bag Emergency kit Item bag labels Twill Tape alphabet stamps stamp pad. Individual item bags https://www.whitearmor.net/forum/topic/56976-asharis-tlj-captain-phasma-build-thread/#findComment-795398 Phasma Build - Packing List.pdf Edited March 11, 2025 by Ashari 1 Quote
Ashari[501st] Posted February 7, 2025 Author Report Posted February 7, 2025 (edited) 7 - Getting Dressed Pre-armor Undersuit Shiny shorts Mic Headset, unplugged Balaclava Neck seal Strapping Harness with Shoulder Gaskets (velcro to harness) Legs Velcro Knee Gaskets to Thigh Slide on Thigh/Knee Gasket Snap Thigh to Strapping Harness Slide on Spats Boots with Toe Plate Add Mid-boot and Back-boot Plates Slide Spats down to make room for Calf & Shin Velcro Calf to Knee Gasket Velcro Shin to Calf Velcro Spats to Calf Velcro Clips to Shin/Calf Torso Kidney Plate Use velcro ties to close Kidney Plate Snap on Cod & Butt Snap elastic Cod to Butt Snap Belt to Kidney Hook Thermal Det to top of Kidney & press into velcro Back Vest goes over head Close Back Vest sides via snaps Velcro AMP to front of Back Vest Plug in Mic Headset to AMP Turn on AMP Velcro Chest to Back Vest Arms Velcro Biceps to Elbow Gasket Slide Bicep/Elbow Gasket on Velcro Biceps to Shoulder Gasket Snap Shoulders to Back Vest Velcro Elbow Gaskets to Gauntlet Finally Cape Turn on Helmet Fans Helmet Gloves Phasma Build - Getting Dressed.pdf Edited March 11, 2025 by Ashari Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 (edited) Build photo galleries: http://imgur.com/a/3o60j2W http://imgur.com/a/ZTBhMQg https://imgur.com/a/captain-phasma-building-part-3-HDCOePM Edited February 15, 2025 by Ashari Quote
gmrhodes13[Staff] Posted February 8, 2025 Report Posted February 8, 2025 3 minutes ago, Ashari said: Build photo galleries: <blockquote class="imgur-embed-pub" lang="en" data-id="a/3o60j2W" ><a href="//imgur.com/a/3o60j2W">Captain Phasma Building</a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script> <blockquote class="imgur-embed-pub" lang="en" data-id="a/ZTBhMQg" ><a href="//imgur.com/a/ZTBhMQg">Captain Phasma Building part 2</a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script> If you use the link with the file extension ie: .jpg, .jpeg, .png, .gif OR right click copy paste your images should show Good how to here 2 Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 hahaha I was just fixing that! 🫣 It's been a while since I've put photos on a forum board! 2 Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 (edited) Sanding box Interior coating with Plastidip Stupid tiny little pinholes everywhere Drying racks - because you don't want stuff drying onto other stuff Edited February 8, 2025 by Ashari 1 Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 And fill, and sand, and fill, and sand.... Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 I've had two pretty stressful things needing to be done during this build; using a rotary tool to cut out the vents is the first one. I've learned that most accidents can be repaired or patched. Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 (edited) There are 16* pieces of armour in this project. Part way in, I realized that I probably won't be dressing myself and it would be much more helpful if things were labelled if they had a side. *16 as in count of each armour type, not including duplicates (rights and lefts), individual foot plates, finger plates, belt boxes or soft parts Edited February 8, 2025 by Ashari Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 Various greeblie parts should have been glued before painting. Have I mentioned this is my first armour build? Ever? Milliput to the rescue! Quote
Ashari[501st] Posted February 8, 2025 Author Report Posted February 8, 2025 Here are some of my genius* ways of supporting pieces during painting and drying... Sealed paper towel roll The upside down towel turban Interconnected box tops The rest of the box 2 Quote
Doggydoc[Staff] Posted February 8, 2025 Report Posted February 8, 2025 Awesome work so far. Very innovative techniques for supporting pieces and I love the sanding box. Great idea. Quote
Ashari[501st] Posted February 9, 2025 Author Report Posted February 9, 2025 Thank you! I'm learning so much. I feel like creative problem solving is how I'm getting through this build.Sent from my Lenovo TB-X606F using Tapatalk Quote
Ashari[501st] Posted February 11, 2025 Author Report Posted February 11, 2025 (edited) I've seen so many troopers in their balaclavas and face coverings. I've often wondered if I could make some improvements for breathability, so I tracked down a pattern (Koa Ski Mask Pattern) and went to work. Would buying a pre-made mask be less sanity stretching and more economical? Yes. Absolutely. But if you're looking for an option that allows you to customize your mask, this pattern was pretty easy to follow and I could print it on my home printer. Fabrics: - Stretch mesh https://www.fabriclandonline.com/products/0057000?variant=34038675275835 - Jersey https://www.fabriclandonline.com/products/2082060 I adjusted the side and top pieces of the pattern to make two pieces and sewed the top half in the stretch mesh. Edited February 11, 2025 by Ashari Quote
Ashari[501st] Posted February 11, 2025 Author Report Posted February 11, 2025 (edited) Transporting a fully chromed set of armor is causing me huge amounts of concern, so I fully upgraded a DEWALT Tough Chest 38-inch 238.5L Mobile Tool Box. Materials: DEWALT Tough Chest 38-inch 238.5L Mobile Tool Box (HomeDepot) SunGlo Soft Foam Cushioning 18 X 18 X 3 Inches (Walmart.ca) Foam Camping Mat (this might not be for sale any more) hometrends Plush Velvet Blanket, Queen size (Walmart.ca) Random foam I had around the house from other projects Multi-Tool (RYOBI 18V ONE+ Lithium-Ion Cordless Multi-Tool) Any long bladed cutting tool (Olfa Heavy-Duty L-1 Cutter 18-mm ABS Plastic and Stainless Steel - Yellow) Any ruler or measuring tape So much hot glue Before starting, my partner cut out the vertical hard plastic guides that were there for adding tool boxes inside the bigger bin. He used the multi-tool to make quick work of them. Then it was a lot of cutting and sizing of foam pieces and SO MUCH hot glue. I measured the interior size after adding the foam and sewed a liner. Reminder: I'm Canadian! So measurements might be metric or imperial depending on the day and my mood 😂 Edited February 12, 2025 by Ashari Quote
Ashari[501st] Posted February 11, 2025 Author Report Posted February 11, 2025 (edited) There are so many pieces to this armor. Continuing my rabbit hole of transportation, I decided to make travel pouches for pieces to prevent rubbing and scraping. Since I'll probably be getting help getting dressed, I wanted to be able to label pieces so anyone could quickly see which was what. I made quick labels out of Twill Tape, some alphabet stamps and a stamp pad. 1x Chest wrap (for both chest vest and chest front) 2x Shoulder wrap 2x Bicep bag 2x Gauntlet bag 1x Glove/hand bag 1x Kidney bag 1x Thermal det bag 1x Belt storage 1x Cod wrap 1x Butt wrap 2x Thigh wrap 2x Knee wrap 2x Shin wrap 1x Boot blanket Plus containers for: Undersuit & neck seal bag Gasket bag Balaclava & shiny shorts bag Shoe bag Emergency kit I found some little premade bags from ikea that I could use to store and organize all the other parts that would've just been floating around. RENSARE Clothes bag, set of 3 Edited February 11, 2025 by Ashari Quote
Ashari[501st] Posted February 11, 2025 Author Report Posted February 11, 2025 (edited) Cape building! Using the cape pattern pieces that were posted in the Captain Phasma Costumers group on facebook, I drew out the pattern pieces on large pieces of paper and added seam allowance. With the vertical seams sewn, I ran out of table space and ended up working on the floor to get the cape hem drawn out. And then moved back to my sewing table to cut the hem out. At this point, I draped it on my dress form to see how it was hanging and if the height looked good. I didn't get a picture of the hem while I was working on it, but the bottom and end hems are done. Once they were finished, I went to painting using Liquitex Gloss Heavy Gel Medium as recommended in the FB group. I chose to do this as one of the last steps because it makes the fabric really stiff and I was worried about my sewing machine handling going through it once the paint dried. Not painting the straps or sealing the pockets closed was a bit of a challenge. I covered the leather straps in painters tape. I painted the pockets, then propped them open with binder clips while I painted the rest of the panel. And one more hang on the dress form to see how it's looking Edited February 11, 2025 by Ashari 1 Quote
themaninthesuitcase[Admin] Posted February 11, 2025 Report Posted February 11, 2025 Wow! Love a comprehensive build thread. Looks like you’ve been making some great progress. Cape looks great too. Love the bags I’ll need to make something a bit like them for my First Order build. Will also have to look into that sanding box. The amount of sanding dust over my work space says I need to! 1 Quote
Sly11[Admin] Posted February 11, 2025 Report Posted February 11, 2025 Truly amazing and inspiring build thread Katie!! 1 Quote
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