Thank you everyone for the kind words... I really do appreciate it
but more seriously am I right in saying that the BB belt allows you to adjust the length with the straps in the back but not the TDK, because of the way it closes in the back? if so the BB model has an advantage that I'll have to consider...
That is a very good observation :thumbsup
I think you are right in saying that TDK back brace is not adjustable as it was tailored to a specific size. I made a back brace with slide tracks for size adjustments but the most you'll get out of it is one or two belt size up because the piece is really not that big. I tossed it and still playing around with another idea but in the end, I don't think it'll be made adjustable.
But if you're planning on wearing the belt, the back is covered by the cape anyways so the way the Begins straps work would be just as good for TDK.
I think these pics will give you guys a pretty good idea of the back connection...
Here's a few pics of the rear plate - front face and underside. The 3 pieces of hardware there are flange nuts. The flanges prevent them from pulling out. They sit and look pretty but also serve an important function.
These pics show how the straps are secured to the plate. And just a quick note about these straps - they were laser-cut in a high density polyethylene. But as you can see, the material doesn't take to laser very well. The final version will use a different material.
Okay, so if you don't think these straps are gonna be strong enough... you may be right
These connection points are not weak... but they are the weakest overall because the back absorbs the weight of the belt. So what can we do to make this area even stronger?
The movie belts also had another strap on the inside. The strap was made from some sort of webbing... ya know, backpack strap stuff. You can use seat belt webbing, nylon, polyester... all are very strong. Poke a few holes, add some grommets, and the flange nuts will secure it in place. Sorry, I don't have any webbing on me at the moment but I'm sure you get the idea.
All in all and for troopers...
The inner strap will bear all the workload. Will provide a virtually unbreakable connection. It is adjustable to whatever length you need it to be. And it's probably a bit more comfortable too.