Vest Question re: Grommet Armour Attachment Method

[Short4ATrooper]

This isn’t really a question as such, I suppose I’m just thinking out loud and want to see if my assumptions are correct. I have my chest armour pieces and I’m waiting on a set of test pieces so I can go about fitting the bolts to my “real” armour pieces ahead of painting.

I’m aware of the technique - drilling holes through test pieces of armour and using those holes to report eyelet locations on the vest, fitting eyelets to the vest and bolts to the armour e.t.c. Whilst researching what size eyelets to use, I came across this old thread where Bobamaker lays out how he does it, which is very similar to the RS Props video in their now discontinued ‘Building Boba Fett’ series (anyone know why they stopped that?)

It differs in one respect though…

In the RS Props video, Rob uses test pieces to report the eyelet holes onto the vest, then puts the bolts though the eyelet holes before applying glue to the bolt heads and then placing the armour pieces directly onto the bolts. The idea of doing it this way makes me INCREDIBLY nervous. One slip and you could end up with a splodge of impossible to remove superglue visible on the vest, or inadvertently glueing the vest itself to the armour. Two possibilities I would love to eliminate if possible!

In the BobaMaker thread, he says “I mark the points on the armour using the same method I did on the jacket.” To me, that means using the test piece holes to report the bolt locations on to the back of the ‘real’ pieces. Here is the relevant step from Bobamaker’s thread:

I can only assume he’s laid the test piece over the back of the real piece to report the bolt locations, like this -

The issue I can see is keeping both pieces properly aligned while they’re stacked. I suppose you could tape them?

 

[BudaFett]

Here's how I've had success with grommet armor attachment without having an armor template or drilling holes.


1) Buy jewelry pins with backing and hot glue them in the spots where you're going to place the nylon screws. Mark the area on the armor.
2) Attach the armor to the vest. Mark on the back of the vest where the pins have been punched through.
3) Punch holes in the vest, attach grommets.
4) Remove jewelry pins from armor and replace them with nylon screws.

 

[Short4ATrooper]

Here's how I've had success with grommet armor attachment without having an armor template or drilling holes.


1) Buy jewelry pins with backing and hot glue them in the spots where you're going to place the nylon screws. Mark the area on the armor.
2) Attach the armor to the vest. Mark on the back of the vest where the pins have been punched through.
3) Punch holes in the vest, attach grommets.
4) Remove jewelry pins from armor and replace them with nylon screws.

This sounds like a pretty good idea. I've already ordered the test pieces from MinuteFett though. He only charged me shipping but I suppose I'd better get some use out of them!

I have no problem drilling holes into the test pieces so I think I'll try what I describe above - use the holes in the test pieces to mark where the eyelets will go on the vest, then lay the 'real' pieces on top of the test pieces and use the holes to mark where to attach the bolts on the real pieces.

 

[Ord Mantell]

I have no problem drilling holes into the test pieces so I think I'll try what I describe above - use the holes in the test pieces to mark where the eyelets will go on the vest, then lay the 'real' pieces on top of the test pieces and use the holes to mark where to attach the bolts on the real pieces.

that is the method used on the original costumes. It works really well.

Post in thread 'Ord Mantell's ESB build'

Sep 2, 2022

My process for mounting the armor on the vest begins with using an extra set of armor with holes drilled in where the posts and grommet holes should mate under the armor.

Place this on some kind of form, either yourself with the help of a friend or on a mannequin of some kind.

Mark where the holes are, and voila. That's where you punch holes in your vest.

Then punch holes.

So how to get the post locations on the armor? Easy, use the same armor you used for the vest to mark the armor you will mount.

...

• Ord Mantell

• 

 

[Short4ATrooper]

that is the method used on the original costumes. It works really well.

Post in thread 'Ord Mantell's ESB build'

Sep 2, 2022

My process for mounting the armor on the vest begins with using an extra set of armor with holes drilled in where the posts and grommet holes should mate under the armor.

Place this on some kind of form, either yourself with the help of a friend or on a mannequin of some kind.

Mark where the holes are, and voila. That's where you punch holes in your vest.

Then punch holes.

So how to get the post locations on the armor? Easy, use the same armor you used for the vest to mark the armor you will mount.

...

• Ord Mantell

• 

Outstanding! Super satisfying that my thinking was correct! And thanks for linking to your thread. My armour is from MinuteFett and I’ve been thinking of getting my flightsuit from clothears, your comments on how great the armour looks with clothears soft parts may have just sealed the deal on that! That 32 week lead time is going to kill me though!

 

[Irongladiator]

Short4ATrooper
You may have seen how I did mine via my WIP thread. And when doing it, I actually didn't do as much research as you did, but knew I wanted to do this method as it seemed like the best way to do it. I've heard about all the other usual methods such as Velcro, Pushback Pins, Magnets, etc. Some people have good luck with it. with others saying sometimes it is a headache to deal with. But, I have not heard one bad thing about the Bolt & Grommet method - aside from that it is an absolute pain to do. But once done, and done right. You're left with a solution that will be hassle free. Most people have said that if you have the 'nerve' to do this, then....

...and so, not being one to back down from a good challenge, I decided to take this on. While this method worked for me, and again I didn't do as much research as you have done, I decided to rough it and find my own way. And without further ado, here is how I did mine....

First up the list of materials.
Qty - Description
23 - 3/8" Brass Grommet (I got 6 in the kit - so I got two additional boxes - from Lowes)
23 - #10-32 Stainless Steel Nylon Locking Nuts
23 - 1/4 Inch Stainless Steel Flat Washers
Tools Used:
Arrow Grommet install kit
Hammer
Hobby Blade
Hot Glue Gun
Gorilla Brand Hot Glue Sticks
JB Weld Plastic Bonder Epoxy (advertised to adhere Metals to Plastics)

I know the above pic shows zinc hardware, but also I initially used hot glue too, while it was secure for about half a dozen troops, the bolts did begin to pop off the armor one at a time. And when that happened, that's when I made the decision to swap them out for Stainless Steel hardware and use epoxy rather than hot glue. Because as most Fett's will tell you (Myself included), you WILL sweat in this costume, and moisture on Zinc does indeed cause rust. And so, since doing this (nearly 5 years later) the bolts have NOT come off using the epoxy, I mean, I have yet to re-affix one bolt. And I've been out dozens of times in my Fett, many times for extended periods.

I eyeballed where the Bolts would be placed and using a drop of Gorilla Glue Gel fixed the bolts in place. I then used the Epoxy around the base of the bolt to secure them to the armor pieces. I let it cure for 72 hours before continuing....

Now the fun part of knowing where to place your grommets as they relate to the where they'll sit on the vest. Especially working with some of the armor that has large curves to it (Like the abdomen armor piece), so you know automatically that the screws are gonna sit funny. But if you take your time with this process you should come out of it good. Again, I eyeballed this and when done - it turned out great I thought! Here was my process in getting the positions of them grommets just right.

Step 1: Place your armor with flat grommet pieces under it, and adjust where needed to get the armor looking right.
Step 2: Using something long and skinny (I used a long scissors) maneuver the grommets in a way that they'll seat the screw just right. Also go under the fabric and gently lift it to see if the screw will land correctly in the grommet.
Step 3: Do Step 2, for all other grommets.
Step 4: Very gently lift the armor leaving the flat grommets in place and then with a sharpie, put a dot in the center of the grommets.

And to install the grommets, here is what I did:
Step 1: Hammer on the grommet cutting tool, which doesn't cut Arkady's material by the way.
Step 2: You can see the circle indent it makes.
Step 3: Using a hobby knife, cut out the hole.
Step 4: You'll also have some padding to deal with underneath, so make sure to clean that out.
Step 5: Using the Grommet Cutting Tool Hammer the hole again. (This is for the reverse side)
Step 6: Flip the Vest over and you should see the indent, Using a hobby knife, cut that piece out.
Step 7: Put on the Grommet.
Step 8: Pound on the Grommet.

Once this was complete (and I have two left to do - Left Shoulder Armor) I was treated with this.....

Armor mounted on great!
That procedure took a few hours and was a very monotonous and tedious task indeed. Just glad it's over. Just a note......but a couple of the Grommets may interfere with the inside pocket that Arkady sews on the inside of the vest.
1) One grommet for me, landed on the inside of the pocket.
2) Another Grommet had me cut the bottom seam of the pocket.

But again armor mounted in this fashion looks great, has never moved on me or embarrassingly come off. I never had to worry about it while trooping.

Hope this helps some folks.

Cheers,
-Iron

 

[Short4ATrooper]

Wow! What a detailed reply, thank you so much - the pictures look great and your full costume is awesome! I hope mine ends up looking half as good!

I've heard about all the other usual methods such as Velcro, Pushback Pins, Magnets, etc. Some people have good luck with it.

Yea, me too. I'm going for 501st approval too and as a general rule, I always try to build according to the secondary level of detail. In this case, the CRL specifies "armor is attached to the vest via the accurate grommet method as shown in visual references."

a couple of the Grommets may interfere with the inside pocket that Arkady sews on the inside of the vest.

My vest is an Arkady so this was very good to know, thank you. Out of interest, what is the pocket for? Is it for the battery pack to the chest lights? I'm very capable with a sewing machine so can always sew a new pocket on if needed.

 

[Irongladiator]

Short4ATrooper

Wow! What a detailed reply, thank you so much - the pictures look great and your full costume is awesome! I hope mine ends up looking half as good!

Thank you, much appreciated! I guess you could say that I enjoy helping people where I can - even if its just with information. Mine may not be the correct way, but it worked for me. In fact, I think the official bolts and nuts are not metal like what I used and more along the lines of this....

...Nylon/Plastic Bolts and Nuts. I considered this, but in thinking longer term, I felt like this wasn't viable. I just know metal would last much, much longer. And so that's what I used. And while the Nylon Plastic Bolts and Nuts are (I think) screen accurate. To me, no ones ever gonna see it or know.

Yea, me too. I'm going for 501st approval too and as a general rule, I always try to build according to the secondary level of detail. In this case, the CRL specifies "armor is attached to the vest via the accurate grommet method as shown in visual references."

While I'm not 'Level II' cert'd, I did get approved within' my Garrison....

And when I went to one of the "Meet-n-Greets" the Garrison holds monthly (Before I was approved), their GML was there and I just happened to bring my flak vest with armor attached. Their GML approached me, complimented me on my work and goes "How did you attach the armor?" I opened up the vest and showed him the inside. He goes "That's impressive. Not many people opt for that method." Sarcastically, I gave him a puzzled look and I went "Oh? And why not?". To which he laughed and replied "Because it is a nerve-wracking pain in the ass to do!"

My vest is an Arkady so this was very good to know, thank you. Out of interest, what is the pocket for? Is it for the battery pack to the chest lights? I'm very capable with a sewing machine so can always sew a new pocket on if needed.

I can only imagine it was meant for the battery pack for the chest lights. But I don't think Arkady's officially said what it was for. But....that's EXACTLY what I use it for. My X3 AA Battery Pack rides in there. Maybe I'll take an updated pic, but a handful of troops later I decided to take my flak vest back to my Alterations Lady, and requested that a large reinforced hole be cut out right where the nut is located. And this is so I can easily get a tool in there to loosen the nut if need be. As opposed to trying to get a small crescent wrench in there to get the nut off. Which was totally worth it.

Best,
-Iron