Another Tie Fighter Pilot Costume

[Nick K]

After the primer was applied and allowed to dry, 2 coats of Gloss Black was put on and in 30minutes I was handling the box and putting the rocker switches on. The grey ones were drilled out to accommodate the 2 LEDs I purchased. Wiring was then soldered to the terminals and the switches glued into position. The wires were then connected to the switch and power supply,which is 2 x AAA batteries in a holder.

 

[Nick K]

I then made the sprocket wheels from thick plastic and added thin plastic to the outer edge where the teeth would be. I put the wheels in the vice and, using a chainsaw file, cut the teeth down to a marked line to get each one the same depth. I then found some plastic tube, which was an old kit part, and cut this to a length that looked right and glued these on. Then I found an old ball point pen that I could use the main body for the inner ring and cut this to the same depth as the outer ring and glued this on. Then, putting three cut-off discs on the shaft of my drill, I cut the slots across the two rings and they looked pretty good. I cut two small black plastic discs to go on the back of each to act as spacers and then I primed and painted them in an acrylic silver spray paint from the Plasticote range.

 

[Blaxmyth]

Then, putting three cut-off discs on the shaft of my drill, I cut the slots across the two rings and they looked pretty good.

Nice tip! Thanks for that!

 

[Nick K]

So, the ComPad. I had made the main surface about three months ago, and finally had gotten round to doing the intricate details. These were just cut from flat plastic to the correct size and glued in place. Having such a large surface of detail, it is a shame that most of it is covered when installed in the sleeve pocket, which only provides a 55mm x 60mm ( that is 21/4" x 21/2" to you guys ) window.

 

[Nick K]

Once the gloss finish was applied to the armor, I set about working out where the shoulder straps were to be located. I then drilled holes through all the components and bolted them together, putting the bolt head through a screw cover base and then popping the top cap on. worked a treat and looks good. The clips for the elastic were bent up from heavy wire weedmat staples. I then feed the elastic strap through these and sewed the strap together.

 

[Nick K]

I also made a holster (RH) for the DL44 I made a while ago, to compliment the outfit. Well, I think that is all. I took it for a spin at a School gala in Paraparaumu, near Wellington, and thoroughly enjoyed myself. It was very rewarding to hear kids and adults alike compliment me on the costume and, although it took nearly 10 months to put together, was very gratifying in the end. You definitely get a buzz out of the experience. Right, 1 troop down, and goodness knows how many more to follow.
Now, what will I build next? OOOHH! I know...

 

[Blaxmyth]

Well done! This thread is a marvellous tutorial as well as a record of a prop journey. :thumbsup