"Captain America, how exciting!" TWS TFA Rescue USO and Ultimates WW2

Re: "Captain America, how exciting!" TWS concept and TFA

Was able to cut the brackets and get them roughly fitted.



Had enough leftover of the leftovers to fill the center void with a styrene star. Since I can't hide the void without serious filling and sanding think building the back side of the star as an insert is a good second.

The next part of the suit is not based on any priority other than the type and availability of materials since I will be scraping the bottom of the barrel for awhile. Sadly, I didn't have enough leather for the boot cuffs and it was too heavy for the helmet. Thankfully, I already have nickle buckle that is close so I will be working on the holster drop.

 
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Re: "Captain America, how exciting!" TWS concept and TFA

Loving it. Are you going to paint it or get it electroplated?
 
Re: "Captain America, how exciting!" TWS concept and TFA

Once everything is added up it certainly would be.

That is a good find Steam but think that might be a future upgrade. I'll be using the leftover Metalizer paint from the steel build.

Here is the source list of materials for the ah,,, budget:lol shield.

Chicago Screws 1/4" Plain 25 Pcs Np Silver
25 - 1.5 Inch Heavy Welded Rectangle Dee Rings
American Terminal CC-250-0-100 1/4-Inch Cable Tie Clamps
3 of Dickies Men's 35Mm Feather Edge Nickel Belt,Brown,44
Marine Hardware - Triangle Ring - WebRiggingSupply.com
Amazon.com: White Sheet .080 x 6 x 12: Toys & Games
CM 2FT Plastic Captain Shield (Black)

The shield is $145.09 materials, $73.06 shipping for a total of $218.15.

The brackets and straps (everything minus the shield) are $86.10 materials, $26.06 shipping for a total of $112.16.

Both costs are minus Paint, Thread, Glue, Tools, and Labor.

So the budget shield is almost half my guess for the aluminum shield.
 
Re: "Captain America, how exciting!" TWS concept and TFA



The brackets have been made from sheet styrene so I didn't need to grind metal outside and retain the good flex of the nylon shield.
The sheet styrene was measured and cut into 2.5 inch wide strips using score and break. Just use a metal straight edge and a sharp hobby knife to score the line and then break the styrene by pushing down on the edge of a table.
This only works with straight edges. For curved holes, drill a hole at the intersection of the two surfaces and for a curved corner just file the point down to the contour using a nail file.

The leather straps are belts from Amazon. Free shipping! And I don't have to dye, punch many holes, stitch the edges, or buy the buckles. Find a good local sale or if possible a quick trip to Ross, or other such inexpensive clothing store, and the cost could be even less.
The steel shield was done with two belts. This time around I bought three so I could have more leather to work with and do the straps differently.



The leather cross straps attach to the brackets with the chicago screws. Drill a 3/16" hole in the bracket, it doesn't matter if the bracket is metal or styrene at this point. Also, punch matching holes in your leather.
The belts that I am using this time are padded so I have to remove material from the backside of the belts. This was done with an old stone grinding disk and a proxxon, any brand will do, I just prefer proxxon after destroying two of an other brand in less than a month.
If you don't want to do this buy wider chicago screws or unpadded belts.

Now when putting the bracket on the shield this is when metal vs plastic is important. The chicago screws are on the backside of the bracket and sit on the shield. For the Nylon shield I drilled a counter sink hole to accommodate the blind head of the screw. For the Steel shield I punched a lip on the metal bracket.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

The angled part of the bracket has been shaped the same was as the straight long pieces just will more attention to detail.



My first version didn't line up properly under the short leather edge straps.... so I had to remake them. The remake is on top.
I could have angled the leather and made it work but the edge of the leather and the edge of the bracket wouldn't have been parallel.... or cut the grove and then the bracket would have been about 3/16" to 1/18" too short and the angle error would have been transferred to the outer edge.

The angled brackets are two long and two short. I will be able to cut the old longs to make the new shorts and then only have to make new shorts.

It is easier to make the center bracket and straps and then do the angles.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

For the handle and arm cuff, use the free running end of the belt with the holes already punched.







The steel shield wasn't as involved as this one since those belts used a clip on buckle with an integrated loop.

Used a leather punch to make the front and back holes then cut the two straight edges with the hobby knife. This allows the pin on the buckle to pass through the belt.

You can see where leather was removed to help ease the fold and fit the buckle better.

Sewed the buckle on by hand cycling the belt in the sewing machine, put on the metal loop, did two other stitch lines and reinforced it all with a single chicago screw.

I kept one belt unaltered while moding the second so I had a reference for the orientation of the buckle and loop.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

Rikarus said:
very very nice work my friend!
Click to expand...

Thanks, I was recently reminded that my intent was more 'how to and learn with me' but have degraded to 'look at what I have done'.

I hope that this little bit will serve to inspire others to have a go. Lord knows that a year ago had no idea that I could mod a Rescue Jacket let alone make a TFA suit.
 
Re: "Captain America, how exciting!" TWS concept and TFA



It was a race to get this while the sun was still out. The angles are the correct pattern but paper. Hopefully, will make the corrected angles tomorrow.

The spun detail was achieved using small squares of 60 grit sand paper and using the edge and molded rings as a guide. Spun the shield in my lap and dragged my finger with the little piece of sand paper.

The only thing glued is the center star. The two strips of the bracket are only clicked in place and held by friction with the original shield brackets. Rather pleased with the fit and feel. Once the rest of the bracket and straps are made... the bracket will be hot glued to the shield, all the leather will be removed and the shield will be painted.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

This is coming along quite nicely. I am loving the details Fly. So good buddy.
 
Re: "Captain America, how exciting!" TWS concept and TFA

Thanks guys, trying to maintain the high standards.

Here are the templates for the angle pieces and the point of the filler star. This is an early posting while glue dries.



I have no idea what the tolerances or, should say, the variances between the production of airsoft shields were.
If in doubt, just use this as a guide and build each part individually on the particular shield so your parts will conform to the actual contour of your shield and fit perfectly to the factory mounting brackets.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

The angled pieces of the brackets were completed.



Two 1/4" wire clips hold each welded rectangle and are attached with a 1/8" pop rivet. The styrene is sandwiched between the top and bottom of the clip to reduce the profile.
The rivet doesn't hold the backside of the clip, that is glued with super glue and held in the carved recess on the back of the shield.



Also, the 1/4" clips had 1/4 molded on top and would have been very visible. That was knocked down using a nail file.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

The completed brackets were hot glued to the back of the shield using the yellowish glue sticks. I had both white sticks and yellow that came with the gun.



Started with the center strips and then attached the angled parts. Once all the pieces were attached and cooled. Ran a bead of glue along the edge to simulate a weld bead and make sure it all stays together.

The seams between the pieces will be quickly filled with putty. The small strips of leather will be made and fitted...then all the leather will be removed and it is painting time.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

Awesome. Again, thanks for all your in-depth info. It will be a great help when I attempt this.
 
Re: "Captain America, how exciting!" TWS concept and TFA

Awesome job on this! It's really coming along nicely :thumbsup
 
Re: "Captain America, how exciting!" TWS concept and TFA

BB, how are things going with your TFA pants and uniform?

Was able to get the short straps installed.



The short length only allowed one chicago screw as opposed to the movie accurate two and the steel shield.
The screw and short strap are free of the bracket. This is opposite of the steel shield which had both the long and short strap chicago screws through the bracket.

The unpainted shield with the new bracket and straps weighs 4.6 lbs.

Kevin, I may have to jump back to the shield painting thread for this but Duplicolor Metalizer specifies temperatures between 60 to 92 and less than 60% humidity.
This time of year if the temp is correct the humidity is 90%+ and when the humidity is 40% the temps are in the 50s. So which of the two evils is the one to ignore, temperature or humidity.
 
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Re: "Captain America, how exciting!" TWS concept and TFA

Hey Fly. Shield looks great. As far as the pants go, I went with two pair of the Berne fisher stripe jeans. I've dyed them both and achieved a shade of blue I'm happy with. Not an exact match for the UD jacket, but a good complimentary color. Used 1 bottle RIT aqua and 3tbs royal blue per 3 gallons H2O. Next step is to ship both pair to roblenzz, who is going to do the sewing for me since I have virtually ZERO sewing skills. Also got my new leather gloves in the mail the other day. Gonna scuff 'em up and paint 'em this weekend. On sale they were $18 I believe...
Men's Leather Gauntlet Cycle Glove - Wilsons Leather
 
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