Rotj Build Up

OK, So I got a few things done today.

First thing that I did today was drill holes for the studs to connect the collar and back plate.

For the studs, i make a line corner to corner to find the center of the stud
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Next i drill a hole just wide enough and deep enough for the bolts i will be using. be very careful not to go too deep here, it is a good idea to wrap tape around the drill bit at the point it will be too deep.
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Next I drill a hole about half the depth of the last hole and just wide enough to fit the nut.
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The nut should be just barely bigger than the second hole drilled. I used some pliers to slowly "push" the nut down into the hole, until the nut is flush with the bottom of the stud.
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I used Rafal template to line up the holes for the collar plate. i Drilled the holes in the collar plate, then lined the collar plate onto the back armor and used a marker to mark the holes for the back armor. Using the studs now I am able to attach the armor together.
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Next, I painted my RKD armor. Last night I prepped the armor( sanding from 60grit to 100grit to 150grit) and dremeled the edges. I also made the slots in the left chest plate bigger for my Fettronics chest lights.

I started with the metallic rustoleum paint, then used a 0000grit steel wool to knock down some of the shine
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Then comes the yellow/orange layer, then the ESB left behind green paint, and finally the top green. I didnt take pics of the stages of masking and painting, because we have all seen it at this point!
Once fully painted i removed the masking and hit everything with more 0000grit steelwool
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Then I took some shots in the sunlight, 20130622_190745.jpg
Then one with the flash outside 20130622_190738.jpg

Next I am going to add some brown and black pastels, but that is a job for tomorrow!

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So I did some weathering and mounting of the armor.
I used magnets to mount the armor, so their placement is customizable and not permanent.
I also added the right chest decal that i got from Bobamaker
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Edit: Added some shots with the armor tweaked to rafal's suggestions!
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I'm an empire guy, but this really makes me think about Jedi. good job.

Exactly my words too!

I really love the look of the helmet and the armor on the mannequin! The collar and the chest plates are in the correct place, the center diamond should be lowered a bit and you should do the same with the abdominal plate too (the lower edge of the abdominal plate should line up with the back plate's lower edge).

How well my new armor stencils (and templates) align to the RKD armor? Are there major differences?

Keep up the great work!
 
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I started with the metallic rustoleum paint, then used a 0000grit steel wool to knock down some of the shine

I never used steel wool at all. Once I had the entire armor completely painted, I sealed it with an over spray of Testors Dullcote, which alone knocked down the shine of the silver from the big dings I had masked off from the base layer (I used Rustoleum Industrial Aluminum as my base layer).
 
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RafalFett- Thanks! That is the nice thing about the magnets, i am able to move the armor anywhere i want! For the armor I "eyeballed" the location. for some reason i couldn't get my graphite paper to transfer onto the rustoleum aluminum paint i used. But I did line up prints of the template onto the armor and "scratched" basic locations of the silver damage through the paper onto the armor to give me a point to start from.Having all the colors separated makes painting a little less overwhelming!

Mr Fett- The steelwool also helps to knock down the overspray, since i am using rattlecans. If i wait till the end to use the steelwool then the paint has a textured or sandpaper feel to it. The steelwool if careful and used softly will eliminate the sandpaper feel and blend the layers of paint. After i weather everything with pastels I will hit everything with some flat clearcoat to seal all the goodness in :)
 
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OK, so today i worked on The Mounting of the Jetpack!
This has been a task I have long feared! The first thing that you need for mounting is the Jetpack hooks, which I have been searching for and so far have been unable to find. I decided to go the route MattyMatt did and use a cheap paint tray for it's hooks. The hooks did require some bending, which i did using a clamp and some pliers.
The hooks were alittle long, so i trimmed them using a dremel.
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Then i used a sanding drum bit and straightened out the cut and rounded off the corners.
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Next I drilled out the three holes that go in each hook, and made sure the bolts fit.
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Next it was time to attach the hooks to the jetpack. To find the right spot to for the hooks on the jetpack I had to create the straps and see where they would hang. To make the strap I used white nylon webbing, taped the ends and then used two thumbtacks to copy the rivets used.
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Since for now this will be a display piece, i am attaching the straps to the back armor plate. I drilled a hole in the strap big enough for the stud bolt to pass through. I use the inside stud bolt to attach the straps to the back plate.
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Next I use duct tape to find the right spot for the hooks. I duct tape them to the back of jetpack and find exactly where they need to be to fit into the straps.
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Once the hooks are placed i measure to find the symmetrical location for each one. Using a white pencil i mark the location for each hole. After drilling all 6 holes, i start to tighten the bolts for the hooks.
I used a set of straps i had made earlier to test the stregth of the hooks on the pack. The test was a success and the jetpack did not fall to it's doom!
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Update on the jetpack, added the greeblie cutout area and a new cutout that is more accurate....
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Once the hooks and the straps are secured, the only thing left to do is to mount the jetpack!
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And now just a couple shots, comments are welcome as far as the placement goes. I can adjust if needed, by about an 1in up and 2in down.
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EDIT- ok, so after checking out some of the images in the ROTJ screen captures, i realize that the pack should be up higher. Tomorrow I will lower the hooks on the pack by probably 1.5in to raise the pack up to what is screen accurate.
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It looks great and I wouldn't change the jetpack's position. The screencap you posted is correct but because he is leaning a bit forward the jetpack is closer to the body. You can use this promo image for the jetpack's position:

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RafalFett- Thanks, I am glad you posted that pic, i didn't like the pack being up so high. So i guess i will leave it where it is!

Ok, So this morning I installed my Fettronics chest light. First I glued in a left over piece from my visor.
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Then I taped down the light board, and glued around the tape to seal the tape down. When I mock installed this, the tape kept coming up and off.
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And finally I permanently installed magnets to the back of all the armor.
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OK so my US Diver Co buckle and belt came today! I'm not sure exactly where it goes, under flak or under girth.
Some close ups of the belt/buckle
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And here are a couple of shots all put together, minus the braids and cape..
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It goes under the vest, yes, not under the girth. It's only visible in some pics, but not in others......so the person wearing it might be the only person who knows that it's even there. LOL - This being said, I've never even owned one of those U.S. Diver buckled belts before because both showing one and not showing one are still accurate to the Lucasfilm reference pics.
 
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Mr Fett- Thanks! I realized after getting the buckle that it is not as noticeable as the esb version, but I have it now and I'm going to use it :)

RafalFett- Thanks a lot! I think I am going to scratch build the guantlets next, do you know a good source for templates?
 
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