The Force Awakens Stormtrooper Armor Build [WIP]

Alright, thermos pep is finished. For whatever reason, this piece took a really long time to make even though it was pretty small. The internal piece is kind of a pain to put together because it is a closed piece. I haven't ever rondo'd anything before, but this might be my first go at it.


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IMO, this thing should not have been two pieces. This configuration will keep the internal cylinder as perfectly straight as possible, which is one upside. I think having it be two pieces significantly increased the size of the hurdle that this pep posed, which is definitely a downside.


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In other news, I started cutting out the pieces for the chest "bib" (putting the arms on hold for now). The only reason I held off on pepping this piece until now is because I wanted to have the sports bra (back/shoulders) piece into the fiberglass phase. Without it as support, the bib could warp/lose shape. I'll probably cover the sports bra in plastic wrap when I resin the bib, just so that it assumes the correct contour. But I am getting ahead of myself.


Speaking of getting ahead of myself, I think I'll be removing a significant amount of material from the sports bra after the bib is into fiberglass. My plan it so determine whether it's feasible to shape the back/shoulders piece into a yoke similar to what Anovos did with theirs. Removing the material underneath the bib would make it so that I don't have to do this chest piece as a two-piece clamshell like I did with Master Chief. The clamshell thing is really annoying -- putting it on correctly requires another person to be around. If possible, it's nice to avoid building in that kind of thing.


The material missing from the top of the piece in this image makes me think I can get away with it:


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We shall see.


Oh, and the helmet is finished with fiberglass for the time being, and I started sanding the exterior with 60 grit. Unfortunately, my sander **** itself. Seriously - there were ball bearings coming out of the bottom of it. Probably what you get for buying a consumer grade electric sander. To prove that I have learned my lesson, I have basically the same one coming in the mail later this week.
 
I'm curious: Is there a specific reason you waited until the fiberglass stage to cut the sports bra? I'm considering just doing it once I've finished the pep stage.
 
I'm curious: Is there a specific reason you waited until the fiberglass stage to cut the sports bra? I'm considering just doing it once I've finished the pep stage.

There is a reason, and I would 100% not recommend cutting it before fiberglass.

Unless you wait until after you are most of the way through the fiberglass stage, the physical structure of the piece is no longer intact. If you were to try to fiberglass the cut piece, you would need to create a lattice of supports that would keep the front portion in its proper place while you fiberglassed it/waited for it to dry. Alternatively, if you leave it as one piece through inner/outer resin and into/through fiberglassing it, you can just not glass the portion that you know you will be removing, and you'll have a lot less trouble with keeping the piece in its proper shape while you work through the fiberglassing process. Basically, there's nothing to be gained from cutting it early, but a lot to lose!
 
There is a reason, and I would 100% not recommend cutting it before fiberglass.

Unless you wait until after you are most of the way through the fiberglass stage, the physical structure of the piece is no longer intact. If you were to try to fiberglass the cut piece, you would need to create a lattice of supports that would keep the front portion in its proper place while you fiberglassed it/waited for it to dry. Alternatively, if you leave it as one piece through inner/outer resin and into/through fiberglassing it, you can just not glass the portion that you know you will be removing, and you'll have a lot less trouble with keeping the piece in its proper shape while you work through the fiberglassing process. Basically, there's nothing to be gained from cutting it early, but a lot to lose!

Very​ good to know! I'll definitely do it that way then, thanks!
 
I agree. I am in the process of building the helmet as well. I just finished fiber glassing it and I am knocking down the sharp edges at the moment. Great job on the pep build. Very clean.
 
Wow! I'm glad I foundyour thread - I am currently also peppong the same set, just behind you with the progress! I have totally balls'd up with not checking the scale - I assumed the default 94% would have been fine, to find the forearms and biceps are too small. Back to the re-print stage!

Will be monitering! Good luck with the build, looks great so far.
 
Question, how are you going to be doing the shin/ankle pieces? I've been doing the measurements/fitting and resizing of the armor pieces before I start my build and I can't get a size where it fits in length yet still able to slide it on my foot. As far as I can tell the Anovos doesn't have a seem, but I'm not certain. I am really struggling with fitting this pep to my size, as I am 5'5" (female) and small framed (pretty muscular as I am an athlete, but yet still pretty skinny haha) Any help gladly appreciated:)
 
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