commander wolfe clone trooper armor

joshslayton

Well-Known Member
A few months back i got commissioned to make commander wolffe clone trooper armor from the star wars the clone wars series. So the first step i looked into is if anybody had made the armor from scratch. I always see people buy the armor kit necer from scratch. So this is the challenge is to start from scratch using pepakura, fiber glass, and some vacuum form parts.


I first did some research to find if any clone trooper pepakura files actually excisted. Unfortunately no. So i had a friend of mine who knows all that 3d printing n stuff and asked him to make some for me.
ImageUploadedByTapatalk1414219142.797862.jpg

Then was the pain of scaling, cutting, and glueing. My client is a little bigger than me in the stomach area so this took a little trial an error
ImageUploadedByTapatalk1414219245.396540.jpg
ImageUploadedByTapatalk1414219255.694534.jpg
ImageUploadedByTapatalk1414219272.024963.jpg
ImageUploadedByTapatalk1414219282.690657.jpg
ImageUploadedByTapatalk1414219292.630663.jpg
ImageUploadedByTapatalk1414219336.918557.jpg

I have peped the cod piece but i havent gotten a picture of it as i tend to forget to take pictures.

Next was fiberglassing my favorite
ImageUploadedByTapatalk1414380779.910360.jpg
ImageUploadedByTapatalk1414380792.483357.jpg

Then came alot of bondo sanding and filling
ImageUploadedByTapatalk1414380819.230962.jpg
ImageUploadedByTapatalk1414380829.751214.jpg
ImageUploadedByTapatalk1414380839.069861.jpg
ImageUploadedByTapatalk1414380851.822531.jpg
ImageUploadedByTapatalk1414380862.637608.jpg
ImageUploadedByTapatalk1414380870.151162.jpg
ImageUploadedByTapatalk1414381050.128925.jpg


For the elbow armor i made a template then cut it out of sintra heating and bending into shape and i cut out some areas in the biceps
ImageUploadedByTapatalk1414380890.486700.jpg
ImageUploadedByTapatalk1414380900.668043.jpg
ImageUploadedByTapatalk1414380911.481461.jpg
ImageUploadedByTapatalk1414380919.668772.jpg
ImageUploadedByTapatalk1414220465.892391.jpg
ImageUploadedByTapatalk1414220474.019050.jpg

For the shin armor piece i thought i try out a new technique. The pep file for the shin armor wasnt as good as the rest so i decided to make a tape dummy of my shin. Then fill it up with foam and do some bondo sanding on it then vaccuum the piece. Not sure of itll work but its worth a try
ImageUploadedByTapatalk1414381017.660152.jpg
ImageUploadedByTapatalk1414381024.788018.jpg

Stay tooned for more updates
 
Last edited:
Back with an update. Well its been pretty slow process ive been just doing bondo work on everything (mostly on the thighs).
So it took literally so many hours and sooo much bondo on getting the right shape for the thighs
ImageUploadedByTapatalk1414731266.300235.jpg
ImageUploadedByTapatalk1414731275.261394.jpg
ImageUploadedByTapatalk1414731282.785615.jpg
ImageUploadedByTapatalk1414731291.280660.jpg
Now i gotta work on the other thigh *sigh*...

The thigh was missing a fee details in the front so i fixed that with sintra, styrene and some more bondo
ImageUploadedByTapatalk1414731423.461693.jpg
ImageUploadedByTapatalk1414731430.741477.jpg

And also i have finished the bondo work on the chest
ImageUploadedByTapatalk1414731489.613490.jpg
ImageUploadedByTapatalk1414731496.690245.jpg
 
Little bit of an update

The right thigh detail is looking pretty smooth
ImageUploadedByTapatalk1415378306.008869.jpg

What i mostly did was just sanding some spot putty
ImageUploadedByTapatalk1415378353.137182.jpg

Then i did some more modeling
ImageUploadedByTapatalk1415378382.363452.jpg
ImageUploadedByTapatalk1415378388.954485.jpg
ImageUploadedByTapatalk1415378394.889674.jpg

I also mostly work on sanding and filling the back but there was not that much to show so no pictures yet

So the last thing i added was some buttons on the right forearm made out of sintra and styrene
ImageUploadedByTapatalk1415378468.888962.jpg
 
Back with an update

Finally finished sanding the back. Looking nice and smooth and i also cut out the back panel
ImageUploadedByTapatalk1415899469.259400.jpg
ImageUploadedByTapatalk1415899490.567067.jpg

Then i cut the chest and back in half
ImageUploadedByTapatalk1415899613.887679.jpg
Fiberglass interior
ImageUploadedByTapatalk1415899628.056495.jpg

Then i made the back panel detail out of sintra
ImageUploadedByTapatalk1415899700.300232.jpg

Then i gave the chest and back a thin coat of spot putty
ImageUploadedByTapatalk1415899768.915553.jpg
ImageUploadedByTapatalk1415899777.422281.jpg
 
EVO3 makes an amazing Commander Wolfe Helmet kit. Sometimes he has them available. Love your armor and progress. Will be watching this.
 
Hey guys its been a while but i got some progress to show!

I pepped the helmet a while back and i rotocasted the inside with smooth cast 320. Alot more cleaner and easier to do than fiberglass
ImageUploadedByTapatalk1422748789.753259.jpg
ImageUploadedByTapatalk1422748806.774816.jpg
ImageUploadedByTapatalk1422748818.427640.jpg
ImageUploadedByTapatalk1422748826.785449.jpg
ImageUploadedByTapatalk1422748837.913979.jpg

Then i finally finished building up the left thigh piece then adding the front detail using sintra and styrene
ImageUploadedByTapatalk1422749117.048468.jpg
ImageUploadedByTapatalk1422749126.540832.jpg

The foam form i made of my shin is all covered in bondo. All is left to do is to make it look like armor
ImageUploadedByTapatalk1422749374.826607.jpg
ImageUploadedByTapatalk1422749446.539553.jpg

The last piece to pepp was the abs peice. I added some cardboard to hold its shape while fiberglassing it
ImageUploadedByTapatalk1422749739.384462.jpg
Quick mock up
ImageUploadedByTapatalk1422749756.343484.jpg

As for the cod piece one half of it is looking promising now on the other side
ImageUploadedByTapatalk1422749987.747285.jpg
ImageUploadedByTapatalk1422750026.057236.jpg
 
Update!

Not that much to show but i am getting some decent work done. The shin is getting close to done just gotta cut the sucker in half so it can be vacuum formed
ImageUploadedByTapatalk1426258781.662110.jpg
ImageUploadedByTapatalk1426258798.261417.jpg

I made the collar pieces out of sintra
ImageUploadedByTapatalk1426258844.611803.jpg
ImageUploadedByTapatalk1426258862.944178.jpg

I also added some clasps and some buckles to make it wearable. Might have to do i suit up soon
ImageUploadedByTapatalk1426259009.133356.jpg
ImageUploadedByTapatalk1426259020.034494.jpg
ImageUploadedByTapatalk1426259028.933469.jpg
 
This is looking great! Thanks for posting this. I would like to build up some armor as well and I appreciate you showing several different approaches.
Subscribed
 
More updates!

I got to working on the handplates witch was arguably the easiest thing to made again made out of sintra
ImageUploadedByTapatalk1426282102.753560.jpg

This is the antenna base on the right shoulder again again made out of sintra
ImageUploadedByTapatalk1426282179.894934.jpg
ImageUploadedByTapatalk1426282190.379719.jpg

The sins were cut in half so it can be vacuum formed with styrene! All it needs is a little bit of spot putty
ImageUploadedByTapatalk1426282297.730692.jpg
ImageUploadedByTapatalk1426282317.247142.jpg
 
Its been a while since an update so lets begin.

I got to vaccuum forming the thighs and shins out of .060 styrene
ImageUploadedByTapatalk1430520806.876696.jpg
ImageUploadedByTapatalk1430520828.156477.jpg
ImageUploadedByTapatalk1430520842.756769.jpg
ImageUploadedByTapatalk1430520868.657169.jpg
ImageUploadedByTapatalk1430520966.994164.jpg

I made the knee piece out sintra like the elbow piece is
ImageUploadedByTapatalk1430521037.661299.jpg
ImageUploadedByTapatalk1430521070.692527.jpg
ImageUploadedByTapatalk1430521101.054920.jpg

As this point I decided to paint the forearms, biceps, and shoulders. I masked off and painted the decals. Needs a little clean up but non the less looks pretty nice
ImageUploadedByTapatalk1430521204.456986.jpg
ImageUploadedByTapatalk1430521256.656212.jpg
ImageUploadedByTapatalk1430521290.801304.jpgImageUploadedByTapatalk1430521413.281295.jpg
 
Its been a while but I finally have an update for the commander wolffe armor.

Ive been prepping the chest, back, and the shins for paint and then masking off the decals
ImageUploadedByTapatalk1440199954.797378.jpg
ImageUploadedByTapatalk1440199966.978229.jpg
ImageUploadedByTapatalk1440199975.811505.jpg
ImageUploadedByTapatalk1440199987.930119.jpg

But other than that ive mostly been working on the helmet. Ive been dreading this part because I had no idea how to turn it to a deferent one. So im just gonna make it up as I go.

So the first thing I did I grinded down the ears and cut the faceplate out styrene. Then I filled in some areas on the helmet woth free foam air.
ImageUploadedByTapatalk1440200479.943234.jpg
ImageUploadedByTapatalk1440200503.194455.jpg
ImageUploadedByTapatalk1440200519.228194.jpg
ImageUploadedByTapatalk1440200547.793161.jpg

I then glued some florist foam and sculpted the tupe breather thing and coated it with epoxy resin then covered that with free form air
ImageUploadedByTapatalk1440200683.042732.jpg
ImageUploadedByTapatalk1440200698.209987.jpg
ImageUploadedByTapatalk1440200710.259215.jpg
ImageUploadedByTapatalk1440200726.426587.jpg
ImageUploadedByTapatalk1440200737.443483.jpg
 
This thread is more than 8 years old.

Your message may be considered spam for the following reasons:

  1. This thread hasn't been active in some time. A new post in this thread might not contribute constructively to this discussion after so long.
If you wish to reply despite these issues, check the box below before replying.
Be aware that malicious compliance may result in more severe penalties.
Back
Top