Agent Kallus Season 1 - Star Wars Rebels

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NoHGRi

New Member
I've been working on my Agent Kallus on and off for a little over a year but finally debuted it at this years' Dutch Comic con.

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All parts (Bo-rifle excluded) are costume build and sized for my posture. I even shaped the helmet around my own head.

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base material is cardboard covered with resin and a lot of plaster :)
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Blaxmyth

Sr Member
RPF PREMIUM MEMBER
What a superb build! Fantastic result!

Feel free to post more pics of the work in progress. The dome with the holes in it turned out really well - how did you do that?
 

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NoHGRi

New Member
@Blaxmyth The extra dome with the holes (for some reason I started calling it the helmet armor :) ) is a piece of fiberglass mat with resin shaped right onto the helmet (which I covered with plastic foil so the resin wouldnt stick to the helmet) and smoothed with a thin layer of plaster

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NoHGRi

New Member
The body armor is also made of cardboard, fiberglass mats and resin and a lot of plaster again :)

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I also tried to shape this to my own chest so it would not turn out to large or small
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I sealed the front with resin and put fiberglass and resin on the inside

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Added a lot of plaster to smoothen it all
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three layers of Silver spray paint, followed by smears of mustard (for battle damage) and two layers of dark grey. And finishing it of with scraping away the mustard and attacking it with my dremel
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shoulder straps (also cardboard) are attached to the front armor with bolts which are then covered with plaster. And attached to the back armor with one bolt each side which is then covered with a cap
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Blaxmyth

Sr Member
RPF PREMIUM MEMBER
Aha! Crafty! :thumbsup

@Blaxmyth The extra dome with the holes (for some reason I started calling it the helmet armor :) ) is a piece of fiberglass mat with resin shaped right onto the helmet (which I covered with plastic foil so the resin wouldnt stick to the helmet) and smoothed with a thin layer of plaster
 

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NoHGRi

New Member
It was decided on the 501st forums that Kallus doesn't wear high boots, but regular black boots with separate shin armour, without any visible seams. So a solid closed armor. Not easy to make, or to get your foot through :)
Luckily I found pvc tubes used for ventilation systems which were wide enough (barely) for me to get my foot through.

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but ofcourse the longest version were about 3 inches to short (its never easy is it) So I had to lengthen them

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which of course is impossible without there being a seam, so back to a plastering and sanding and plastering

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After a lot of discussions on the 501st forum it was also decided the gloves were not just gloves, but also part armour.
These I made out of pvc sewer tubes cut to shape, heated and bend appropriately.

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