Poe Dameron / Resistance Pilot Harness DONE! (Found parts, webbing, etc.)

Ponte

Active Member
UPDATE 13 Dec 2015: Ejection harness is completely finished!

Final Belt Sale Front.png

I wanted to start a new build thread for a screen accurate, found parts harness system for the Resistance Pilots in the upcoming "The Force Awakens" film, specifically using Poe's as the template. A few people have been asking me to come up with some, and from what I've seen so far, everyone (including our dapper new hero) has nearly identical rigs.

Instead of tacking on a bunch of new info and cluttering up the other Poe thread that's working on flight suits, gloves, boots, etc, I wanted to dedicate this thread to nailing the exact components and construction for the harness. Luckily, we know that these parts (along with almost everything else in this film) were mostly UK/EU militaria that's been modified and dyed to create the amazing harness we see on these pilots. There's a few components to the rig that are cotton webbing most likely taken from a giant spool of various sizes, but we'll go into that later on in the thread.

There's something that needs clarification: The roll-pin buckle. Like any surplus manufacturer, there are different sizes/shapes/patterns of hardware offered on the market. While I assumed that the buckle was initially the brassy color most of the base-belts use, the real one is in fact from a completely different source.

On the left is the "bare metal" buckle that's compared to images of Poe's harness. On the right is the incorrect, yet more plentiful buckle that we see on a lot of the belts being offered. There are some pretty distinct differences in the construction of the buckle, namely the size (bare is bigger), the lip (again, bigger), and how tightly they were stamped (bare has more of a gap)
Buckle Compare 1.png

Hooray for conveniently orange wall stripe! This shows the exact buckle when compared to the real deal. You'll notice both Poe's and mine have the open "lips", and the crease is much softer than the brass version.
Buckle Compare 2.png

Here's what I mean (left is brass, right is bare)
Buckle Compare 3.png

You'll notice how tight the crease on the brass is compared to the correct bare buckle.
Buckle Compare 3a.png

Well...had to get three; both side straps and center buckle.
Buckle Compare 4.png

I'm still awaiting more materials from the UK (shipping stinks). Hopefully by tomorrow, I'll receive some base belts to play with, as well as the other webbing to make up the rest of the rig.

Oh, and to further complicate things, the base belts were totally ripped apart, cut, and sewn back together to accommodate the wearer's waist since it's flipped inside out. You can tell by the additional webbing found near his center buckle, and the fact that there's NO WAY the stock belt fits tiny-waist Oscar Isaac in this configuration. That'll come next post...

Poe Dameron.png
 
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Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

great information...I have been looking over some new information too....I know that there will be a lot of re-doing of what I have done so far as more information comes out
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Good eye, man! I think the "almost correct" ones will do when the finis is removed, but I do agree with your analysis!
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

I guessing that buckle is not brass nor brass plated. The brassy color is due to some sort of residue/tarnish during the manufacturing process.

I have run into this before as I have been acquiring and selling buckles like this for the X-Wing Pilot costumes.

To fix this issue, you need a mix of vinegar and salt. (if I remember correctly, 1/4 cup vinegar to 1 tsp of salt for 15 to 30 minutes). Rinse under cold water. You may need some sort of small brush to get the flakes out of the knurled areas.

Here is a picture. The buckle on top has been cleaned using this process. It used to look like the buckle below it.

image_zpsf4da8a34.jpg
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

I guessing that buckle is not brass nor brass plated. The brassy color is due to some sort of residue/tarnish during the manufacturing process.

I have run into this before as I have been acquiring and selling buckles like this for the X-Wing Pilot costumes.

To fix this issue, you need a mix of vinegar and salt. (if I remember correctly, 1/4 cup vinegar to 1 tsp of salt for 15 to 30 minutes). Rinse under cold water. You may need some sort of small brush to get the flakes out of the knurled areas.

Here is a picture. The buckle on top has been cleaned using this process. It used to look like the buckle below it.

http://i1279.photobucket.com/albums/y529/bonofl/Buckle/image_zpsf4da8a34.jpg

"Brass" is the terminology I'm using for the tarnished buckle to differentiate it from the "Bare" buckle, but yes, it is definitely a tarnish and not an intended coating. As noted, there are inherent physical differences in thickness, dimensions, and how tightly the lips were stamped between the tarnished buckle and the non-tarnished. Most likely different manufacturing plants.

It's possible other Resistance Pilot harnesses might have the brass-tarnished buckle, as I'm sure they had to scoop up A LOT of webbing for the extras, but for this build, I definitely want to go the route of using the found buckle (the bare metal) since it adheres to the correct dimensions and construction of Poe's hero harness.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Good analysis on the buckles. Any idea what the loops are that have the side buckles attached to them? It looks like the straps that hang down are not as wide and those loops don't appear to be the same as the belts. Is it the cheaper version of the belt with the buckle swapped out for a better one (wouldn't really make a lot of sense)? Or do you think they made it from a webbing by the meter? Here's a link to the cheaper, inaccurate belt I mentioned:

http://www.ebay.com/itm/291413935136?_trksid=p2055119.m1438.l2649&ssPageName=STRK:MEBIDX:IT

Also, do you know a good source for the buckles? There are a couple sellers on ebay, but their shipping prices, particularly for combined shipping, are ludicrous. I'll order from them if I have to, but I don't like supporting people that rip off their customers.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Good analysis on the buckles. Any idea what the loops are that have the side buckles attached to them? It looks like the straps that hang down are not as wide and those loops don't appear to be the same as the belts. Is it the cheaper version of the belt with the buckle swapped out for a better one (wouldn't really make a lot of sense)? Or do you think they made it from a webbing by the meter? Here's a link to the cheaper, inaccurate belt I mentioned:

http://www.ebay.com/itm/291413935136?_trksid=p2055119.m1438.l2649&ssPageName=STRK:MEBIDX:IT

Also, do you know a good source for the buckles? There are a couple sellers on ebay, but their shipping prices, particularly for combined shipping, are ludicrous. I'll order from them if I have to, but I don't like supporting people that rip off their customers.


Looks to me like the "ejection harness" is just standard webbing in a grosgrain weave about 1.5" wide (or more likely, something close in metric sizes).
I haven't personally located a source for the super accurate buckles, but the "close enough" buckles can be had from a company called "contact left" in the UK. They were about $5 each after you figuree in shipping. Just soak the buckle in a vinegar and slt solution for 15 minutes and then wipe off the anti-corrosion coating. Rinse well and hit with an anti-rust agent afterward or they will rust.
 
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Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

"Brass" is the terminology I'm using for the tarnished buckle to differentiate it from the "Bare" buckle, but yes, it is definitely a tarnish and not an intended coating.
That looks to me like cheap zink-plating. Hardware such as screw, bolts and nuts are often plated that way for rust-proofing - and those tend to be much cheaper than the black-oxidized or stainless counterparts.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

That looks to me like cheap zink-plating. Hardware such as screw, bolts and nuts are often plated that way for rust-proofing - and those tend to be much cheaper than the black-oxidized or stainless counterparts.

Probably correct. It's definitely some sort of anti-rust treatment. It comes right off with the vinegar soak and scrubber pad. Heck, most of it came off with a finger rub.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Are you the original owner of this photo? If so can we get a higher res scan? He has a badge on his left chest.
It's a picture from a magazine (or maybe it was on one of the magazine websites, I can't remember). The picture has been around for a little while, though without the text. I'll see if I have the other picture saved... I can't remember if I do or not... But I'm sure someone else has it if nothing else.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Finally got my base belts in the mail, and I have to say this part was THE most puzzling to figure out, but I think I've got it. While the current photos of Poe we have out in the public aren't the best, some of them definitely give us enough of a glimpse as to how the belt is not only put together, but how it's fastened as well. I needed TWO base belts in order to create the extension. Each belt has two layers: a main layer, and an inner layer. Both layers need to be separated and resewn together like the screen-used belt.

First things first: The way the buckles are sewn to this belt from the factory are NOT correct for Poe's rig (and they're the wrong buckle too). That section was removed and replaced with the inner belt layer and looped through the buckle and to the back of the belt as shown. You can tell by the difference in material that transitions from "main belt" to "inner belt". You'll also be getting rid of the original "connecting strap" that's sewn into the belt to originally go through the buckle, since it's not used on the props.

Belt Altering.png

This is only placed temporarily, but when the inner belt is eventually sewn to the main belt, it'll only go so far. That's where the second inner belt comes in, and is sewn as an "extension" to the main belt. You'll see why next.

DSC_0490.jpgDSC_0491.jpg

Bear with me on this one. Basically, the main belt AND inner belt are looped through the buckle and overlap the "buckle side" of the belt. You can clearly see the multiple layers of belt that are on his right past the buckle. My guess is that the main belt should have stopped where the buckle met, however, Oscar Isaac's waist is TINY (probably a 29 or 30), so he took the excess and fed it through the buckle.

Belt Configuration.png

As luck would have it, I was able to source the correct cotton webbing from a UK supplier that "sold to a production company in the hundreds of yards"....take what you will from that. It should be here by next week, and I'll be able to start working on the side straps.

Can't wait for the next phase!
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Looking nice!

It definitely does appear that the TFA costumers made the belt themselves, which would explain why no one can find the right color in the real military belts. But for one, the TFA belt has stitching on the top of the ribs that the real belt doesn't seem to have, or at least I can't see it. The ribs are also a different width.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Looking nice!

It definitely does appear that the TFA costumers made the belt themselves, which would explain why no one can find the right color in the real military belts. But for one, the TFA belt has stitching on the top of the ribs that the real belt doesn't seem to have, or at least I can't see it. The ribs are also a different width.

Thanks, this is definitely shaping up at a decent pace, although waiting for UK supplies kinda throws a wrench into steady progress.

As far as the color of the belts, these are definitely dyed, and in regards to the stitching on the very top/bottom of the main belt, that has yet to be applied. When these belts were sewn together, the costuming department used white thread post-dye and then the entire belt was given some weathering, discoloring some of the thread. I believe the "stitching" that you see directly over the ribs is the hardened edge that tac-gear manufacturers get by burning the ends so that it doesn't fray.

The width of the ribs is the same, I just think the camera angles might make it seem a bit off. There's really only 2 manufacturers that make these belts (with extremely subtle variants, such as the rear rings and fastener loops) and I'd imagine they could have ordered the base belts by the dozens with relative ease.

This week I'll be doing some dye bath experiments to figure out a solid dye to water ratio for these belts. They absorb VERY well, and only a quarter packet of Rit Pearl Gray turned one of my test belts to charcoal. I'll be using about a teaspoon of liquid RIT at a time on some test webbing to see how that ends up.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

I ended up using "Design Master" paint...in "flannel gray" on my belt and was pleased with the outcome.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Wow, I really like the detail of your build here!
I just started with my belt today and found this, thanks for sharing!
I am also interested in the correct roll pin buckle and was wondering if you could point me in the right direction (if they are offered on the web...).
I will most likely use a separate inner belt webbing I have, since this part won't be so visible... ;)

Sigge
 
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Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

Unfortunately despite the image showing the correct style the roll pin buckles on the belts supplied are very new and do not have the correct look/style.

The buckles on the NYC display appear to be the "newer" style, though I'll admit, I think the differences are extremely slight, so it's hard to tell. I can;t post the pics here, because they do not belong to me, but take a look around, there are lots out there. The buckles have the tighter crease, and the sharper corner.
 
Re: Poe Dameron / Resistance Pilot Harness (Found parts, webbing, etc.)

How did those dye tests turn out for you? I'm trying to decide on dye or paint for my belt right now.
 
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