I received my big box of parts a couple weeks ago, and got started on the building of my clone commander costume.
This is what came in the boxes. It's a full set of clone armour, with a foam latex belt & ammo boxes, foam latex knee and elbow pad inserts, rubberized straps for the shoulders, elbows, knees, and boots, a command cauldron, and a Phase 2 clone helmet with binocs. Pretty much everything I need, aside from boots and an under suit.
I did a quick test fit of some of the parts I was working on here. All of the limb parts have to fit together seamlessly, with no visible join line between clamshell halves. It's a lot of cutting, scraping, test-fitting, etc. to ensure a close seam between halves. As well, the armour is supposed to be very form-fitting. I got it as narrow as I dare at the wrists while still being able to get my gloved hand through. It is supposed to flare out a bit at the elbow. These halves are glued together with CA glue and a shim on the inside to bind the halves together. The elbow pad itself has only a very rough trim right now, and is there just to see how close or far it is from the other parts. At this stage, I was trimming and test-fitting the upper armour parts. This is as narrow as I can get them before I start lopping off detail, so that's where they're gonna get glued.
With all that trimming, the return edges may not line up any more. They are supposed to. I'll cut out the penciled-in area with a utility knife and a razor saw.
I glued a spare piece of plastic behind this cut to give the loose flap something to glue to. I'll fill it in with a bunch of ABS sludge paste. I use ABS because I'm afraid Bondo filler won't flex the same way the ABS parts would under use, and I may get cracks where the filler is. Shouldn't be a problem if my filler is the same stuff the armour is made of.
Here are the two forearms after my little repair job. I'll try to get some ABS filler on them over the next couple days.
I also glued together the upper arms.