Page 1 of 2 12 LastLast
Subscribe
  1. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 8, 2005, 8:06 PM - Aluminum Backplate Progress #1

    As I mentioned in this thread http://forums.thedentedhelmet.com/showthread.php?t=6107 I have started working on my aluminum backplate, which will mate up with my resized collar armor.

    I customized my template, starting with a couple of the templates available on this site, adding in some details from the MOM & ASW reference photos. I then fit the size of the armor to my back, and finnaly tweeked it to match up with my collar armor.

    Using the template I cut a 24"x24" piece of .090 aluminum to the pattern with a metal blade in my jig saw. I then used a bench grinder and my dremel to clean up the edges.

    Next steps are to shape the armor to my back.

    Gator
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack01.jpg 
Views:	1189 
Size:	39.5 KB 
ID:	1137   Click image for larger version. 

Name:	GatorBack02.jpg 
Views:	1161 
Size:	44.8 KB 
ID:	1138   Click image for larger version. 

Name:	GatorBack03.jpg 
Views:	1170 
Size:	42.9 KB 
ID:	1139  

  2. Jango's kid's Avatar
    Member Since
    Nov 2002
    Posts
    2,517
    Mar 8, 2005, 10:09 PM - Re: Aluminum Backplate Progress #2

    pretty cool so far. How are you planning to do the shaping??? I don't know if its still up, but one of our members, Megalomanicalmandalore ,had a great tutoril on how to shape metal armour using a ball pean hammer and other tools. I think he had links to his own site. Might want to check that out if you get a chance. Keep us posted

    Damian
  3. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 11, 2005, 8:58 PM - Re: Aluminum Backplate Progress #3

    I made some progress on shaping my back armor. I used my pannel beater bag and teardrop hammer to shape the plate. It was alot harder than my collar armor. The combination curves along the collar portion of the back plate, across the shoulders and down under the arms we tough.

    I also had to put a slight crease down the center of the plate, and add some curve through the shoulder blade area to get it to fit correctly. I still have some tweeking to do, but I am happy with how it is comming along.

    My next step is to smooth out the hammer blows with a planishing hammer and steel die. Then cut the JP harnes holes, sand, tweek, and paint.

    Gator
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack04.jpg 
Views:	1122 
Size:	40.4 KB 
ID:	1173   Click image for larger version. 

Name:	GatorBack05.jpg 
Views:	1110 
Size:	40.5 KB 
ID:	1174   Click image for larger version. 

Name:	GatorBack06.jpg 
Views:	1109 
Size:	43.4 KB 
ID:	1175  

    Click image for larger version. 

Name:	GatorBack07.jpg 
Views:	1127 
Size:	38.9 KB 
ID:	1176   Click image for larger version. 

Name:	GatorBack08.jpg 
Views:	1117 
Size:	37.9 KB 
ID:	1177  
  4. wizardofflight's Avatar
    Member Since
    Nov 2004
    Posts
    991
    Mar 12, 2005, 12:42 AM - Re: Aluminum Backplate Progress #4

    Excellent work, thank you for sharing your progress shots. Keep posting!

    Alan
  5. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 14, 2005, 9:16 PM - Re: Aluminum Backplate Progress #5

    I started to smooth out the shaping hammer blows with my new fender hammer and dolly set. The set is made for working on auto body fenders, but works just as well on mandalorian armor.

    The steel dolly is held on one side of the plate, while you hammer the bumps from the other side. You then switch from side to side to even out the high and low spots on each side of the plate. An english wheel would have worked great, but I could not get ahold of Jessie James at West Coast Choppers.

    I sanded the outside of the backplate to reveal the high and low spots, then used the hammer and dolly to smooth them down. I think I will repeat the hammer / sanding process a couple more times on the left side, then move to the right.

    Gator
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack09.jpg 
Views:	1067 
Size:	59.5 KB 
ID:	1276   Click image for larger version. 

Name:	GatorBack10.jpg 
Views:	1085 
Size:	57.5 KB 
ID:	1277   Click image for larger version. 

Name:	GatorBack11.jpg 
Views:	1090 
Size:	55.5 KB 
ID:	1278  

    Click image for larger version. 

Name:	GatorBack12.jpg 
Views:	1106 
Size:	57.5 KB 
ID:	1279  
  6. propsculptor's Avatar
    Member Since
    Oct 2003
    Posts
    322
    Mar 14, 2005, 10:53 PM - Re: Aluminum Backplate Progress #6

    Quote Gator Fett said:
    I started to smooth out the shaping hammer blows with my new fender hammer and dolly set. The set is made for working on auto body fenders, but works just as well on mandalorian armor.

    The steel dolly is held on one side of the plate, while you hammer the bumps from the other side. You then switch from side to side to even out the high and low spots on each side of the plate. An english wheel would have worked great, but I could not get ahold of Jessie James at West Coast Choppers.

    I sanded the outside of the backplate to reveal the high and low spots, then used the hammer and dolly to smooth them down. I think I will repeat the hammer / sanding process a couple more times on the left side, then move to the right.

    Gator
    Great job on the smoothing of the metal,
    where can I pick up a fender hammer and dolly set?
  7. BobaFettSlave_1's Avatar
    Member Since
    Oct 2004
    Posts
    1,716
    Mar 15, 2005, 5:12 AM - Re: Aluminum Backplate Progress #7

    awsome!
  8. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 15, 2005, 6:53 AM - Re: Aluminum Backplate Progress #8

    propsculptor - I bought my pannel beater bag and my fender hammer & dolly set at Eastwood Company Automotive online. There website is:

    www.eastwoodco.com

    The pannel beater bag set is:

    www.eastwoodco.com/shopping/product/detailmain.jsp?itemID=1482&itemType=PRODUCT&iMainC at=489&iSubCat=492&iProductID=1482

    The fender hammer & dolly set is:

    www.eastwoodco.com/shopping/product/detailmain.jsp?itemID=1704&itemType=PRODUCT&iMainC at=504&iSubCat=505&iProductID=1704

    BobaFettSlave_1 - Thanks.
  9. BobaFettSlave_1's Avatar
    Member Since
    Oct 2004
    Posts
    1,716
    Mar 15, 2005, 7:04 AM - Re: Aluminum Backplate Progress #9

    where did you get a sheat of aluminum that thick?
  10. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 15, 2005, 7:47 AM - Re: Aluminum Backplate Progress #10

    Quote BobaFettSlave_1 said:
    where did you get a sheat of aluminum that thick?
    I went to a local metal distributor in my area. Look in the Yellow Pages under Aluminum or Metal or Steel to find a distributor in your area.

    For my collar armor, I bought a scrap piece of 1/8" (.125") thick aluminum for about $12. For my backplate I wanted it a little thinner, so I got the next size smaller .090" thick aluminum. They had to cut a 2'x2' pice from a full sheet, so the price was a little more. It came to about $27.

    Gator
  11. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 15, 2005, 9:51 PM - Re: Aluminum Backplate Progress #11

    Well, I finished the smoothing and sanding. I'll consider any left over rough spots battle damage.

    I stuck the colar armor on with some duct tape, and put both pieces on over my vest, to test the fit. While I had the backplate on, I had my wife mark the location of the JP slots from my vest on the armor. I then consulted the MoM reference photos to get the final location for the slots. I marked the backplate where I need to cut the slots, add a dent, and trim the neck line collar area. But that's tomorrow's project.

    Gator
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack13.jpg 
Views:	1048 
Size:	65.9 KB 
ID:	1311   Click image for larger version. 

Name:	GatorBack15.jpg 
Views:	1021 
Size:	63.6 KB 
ID:	1312   Click image for larger version. 

Name:	GatorBack14.jpg 
Views:	1013 
Size:	69.1 KB 
ID:	1313  

  12. Member Since
    Dec 2002
    Posts
    722
    Mar 16, 2005, 8:41 AM - Re: Aluminum Backplate Progress #12

    Like that metal work. Keep it coming
  13. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 18, 2005, 10:18 PM - Re: Aluminum Backplate Progress #13

    I got the Jet Pack slots cut and formed, the neck and shoulder area trimmed and the collar plate attached. I gave both pieces a final sanding, so they should be ready for paint.

    Any feedback or suggestions for changes or improvements? All comments and constructive criticisim is welcome.

    Gator
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack16.jpg 
Views:	999 
Size:	59.1 KB 
ID:	1383   Click image for larger version. 

Name:	GatorBack19.jpg 
Views:	1021 
Size:	52.7 KB 
ID:	1388   Click image for larger version. 

Name:	GatorBack21.jpg 
Views:	1009 
Size:	49.4 KB 
ID:	1390  

    Click image for larger version. 

Name:	GatorBack20.jpg 
Views:	979 
Size:	37.5 KB 
ID:	1392   Click image for larger version. 

Name:	GatorBack24.jpg 
Views:	987 
Size:	48.0 KB 
ID:	1393  
  14. shortimer52's Avatar
    Member Since
    Nov 2004
    Posts
    2,287
    Mar 18, 2005, 10:39 PM - Re: Aluminum Backplate Progress #14

    looking good
  15. Mar 18, 2005, 10:40 PM - Re: Aluminum Backplate Progress #15

    That's lookin sweet! One question, does the weight of the back plate pull your collar armor into the front of your neck?
  16. cal196's Avatar
    Member Since
    Aug 2004
    Posts
    2,617
    Mar 19, 2005, 6:40 AM - Re: Aluminum Backplate Progress #16

    looks great, its aluminum what weight?
  17. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 19, 2005, 7:05 AM - Re: Aluminum Backplate Progress #17

    shortimer52 - Thanks.

    stormtrooper - I don't know. I don't have a jet pack yet. My MLC is on the way, so I will let you know in a few weeks. However, my plan is to secure the JP at the top with the two shoulder straps and at the bottom with a waist strap. Similar to the way the real deal is supported. This should take some of the weight of the JP off the shoulder area and move it down to the bottom of the pack. Besides, the MLC is only 5 lbs. so it should not pull to much.

    EDIT: :o Sorry stormtrooper, I should have paid attention to your question. No, the backplate does not pull on the collar. The way I formed the two pieces all the weight is directly on my shoulders.

    cal196 - The collar and backplate together weigh 1.5 - 2 lbs. My scale sucks so I can't be too sure.
    Last edited by Gator Fett; Mar 19, 2005 at 7:10 AM. Reason: Did not pay attention.
  18. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Mar 26, 2005, 6:44 AM - Re: Aluminum Backplate Progress #18

    I painted the collar and backplate over the past few days. I still have some topical damage to apply and I have to weather all of my armor pieces, but here are a few shots.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack25.jpg 
Views:	955 
Size:	32.7 KB 
ID:	1608   Click image for larger version. 

Name:	GatorBack26.jpg 
Views:	949 
Size:	35.3 KB 
ID:	1609   Click image for larger version. 

Name:	GatorBack27.jpg 
Views:	953 
Size:	55.6 KB 
ID:	1610  

  19. jarodpenn's Avatar
    Member Since
    Nov 2004
    Posts
    236
    Apr 13, 2005, 10:22 AM - Re: Aluminum Backplate Progress #19

    Holy cow, I can't even believe I'm seeing this! You're amazing!
  20. lilburndiablo's Avatar
    Member Since
    Jun 2004
    Posts
    1,791
    Apr 13, 2005, 11:45 PM - Re: Aluminum Backplate Progress #20

    With patience . . .

    Comes wisdom . . .

    Good job!
  21. Apr 14, 2005, 8:23 AM - Re: Aluminum Backplate Progress #21

    Applause!!!!....very good paint job on some sweet metal armor...
  22. Gator Fett's Avatar
    Member Since
    Apr 2002
    Posts
    806
    Apr 27, 2005, 8:45 PM - Re: Aluminum Backplate Progress #22

    jarodpenn, lilburndiablo & stormtrooper - Thanks guys.

    Well everyone, I think this may be my last update on my backplate. I do believe I am finished with this part of my suit.

    I decided to use the rare earth magnets on my back plate and collar armor. The two pieces are screwed together with the shoulder bolts, and I slip the two pieces on over my head. Once on, the weight of the collar and backplate rests on my shoulders. The magnets are there just to hold the armor in position and hold the vest tight to the armor.

    I also finished the weathering for my armor using the blackwash method that others have used. Black acrylic paint mixed with windshield washer fluid, and misted on the armor.

    What do you think so far?

    p.s. See my other thread for the front side, including my chest pieces.

    Gator
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	GatorBack28.jpg 
Views:	841 
Size:	65.8 KB 
ID:	2630   Click image for larger version. 

Name:	GatorBack29.jpg 
Views:	839 
Size:	68.1 KB 
ID:	2631   Click image for larger version. 

Name:	GatorBack30.jpg 
Views:	850 
Size:	49.9 KB 
ID:	2632  

  23. Spideyfett is offline Spideyfett
    Apr 27, 2005, 9:17 PM - Re: Aluminum Backplate Progress #23

    ......Seriously...you have some SERIOUS skills...:thumbup
  24. T-Bone's Avatar
    Member Since
    Jun 2003
    Posts
    965
    Apr 27, 2005, 9:18 PM - Re: Aluminum Backplate Progress #24

    Be proud of your work man, 'cause that looks awesome! Sweet!
  25. FettTheHunter's Avatar
    Member Since
    Jul 2004
    Posts
    405
    Apr 28, 2005, 2:37 AM - Re: Aluminum Backplate Progress #25

    Wow !!! ... that is very impressive work !!!

Similar Threads

  1. Aluminum Flamethrower Progress
    By CombatBaby in forum Boba Fett Costume
    Replies: 2
    Last Post: May 23, 2008, 1:28 PM
  2. tk7602's HS Aluminum Helmet Progress
    By stormtrooperguy in forum Boba Fett Helmet
    Replies: 28
    Last Post: Jan 20, 2008, 8:42 PM
  3. Backplate
    By mobius in forum Boba Fett Costume
    Replies: 3
    Last Post: Nov 24, 2003, 7:44 AM
  4. MMM's Aluminum Backplate
    By MegalomaniacalMandalore in forum Boba Fett Costume
    Replies: 17
    Last Post: Mar 2, 2003, 3:44 AM