Dart

The other issue is durability. Even if you print it with ABS, it's not really the same strength as a sheet of vac-formed ABS. Even though there isn't a ton of armour, it's located at bendy points and gets stressed and eventually cracked. If you can find an approvable design, that'd be sweet!

The KS helmet isn't too bad to assemble, just take your time. There's a few spots that need some tlc (the wrap around may need to be heated and bent in a bit to keep its shape, and the stickers are meh). I'd strongly suggest you do not use glue to assemble the helmet. Years ago, I stuck mine together with some 3M indoor/outdoor foam tape. It's sticks like crazy once it cures but it gives you a bit of wiggle room if you need to rip it off and try again.

Lookin' good!

If you're replacing the chest, you'll likely have to replace the back as well. Some armour you can mix and match, but I'm not sure a KS back will match up with as SC chest.

Hi Andrew, Unfortunately, the only templates I've ever seen were some pepakura files but they weren't too accurate. For kids, I'm sure they're fine as a base. As for using foam bits for yourself, I'd suggest you save your time as the armour must be of the hard plastic variety for 501st approval.

Hi Patrick, Welcome to BS.N! Don't worry about your size. I'm 6'2", 260 lbs and I fit into mine fine.

*coughmidcoatcough*

And it fits her very well, I might add. SC is easily a great choice.

So we'll wait until they're almost done, then the chinese factory that's making them will flood and then they'll have to start all over again 3 years later. If I wasn't so optimistic I'd be done with these guys already...

I just hot glued some blocks of foam where I needed it. It can take some trial and error to get a good fit.

Luc, you won't go wrong with SC.

Great work! So... any chance you're planning on giving BS.N Armourers a sweet deal on some new armour? *wink, wink*

Yet another scout! Lemme know if you have any questions!

I always tell my scouts to paint the black bit so that the edge is halfway across the front of the snout edge, much like the above photos. The paint should really not stop at the inside edge of the snout.

I use my snout for ventilation. I got a hollow snout from MonCal that comes with some mesh. Drilled through that and my helmet's faceplate. I installed a ducted (squirrel) fan to blow up towards my lens. Never had a problem except when walking behind smelly people (then the fan gets turned off, ha!). I'd strongly advise against making any holes that aren't supposed to be there. Armour ain't cheap and finding out the hard way that it's not approvable after doing mods sucks.

Groovy! Congrats!

Before you go stitching that on, be sure that it's far out enough on your thigh (the front edge should be at the middle front of your thighs). You can cheat a bit by splitting the legs on the pants down the outside seam, and then stitch the riding patches down. Afterwards, just re-stitch the outer seam and you're good to go.

Looks good so far!

That looks about right. Depending on how big around your thighs are, you'll need at least 2, maybe 3 (1 of those will be the mudflap). If it was me, I'd rather get more than less and have extra just in case.

Call me crazy, but it actually just looks like a Kenner blaster that's either been painted or is just super clean, without the stickers.

My 'bund is sewn to my vest. No problems there. I also have a velcro tab that sticks to the inside of the chest armour.

They don't need to go that far around. Just to the inside back of the thigh. Sit on a stool and see where your thigh hits at the back. Make it that deep.

Agreed. I'd knock off an inch from the bottom of the 'bund and trim the bottom of the shoulder bells then reshape the corners. Ideally, you want those bicep bits above the elbow, maybe at least 2 cm/ 1 inch higher than where you have them now. Also, and this is more a dressing point, You can roll those shoulder bells to the front a bit more. The tops are sitting where they should, just need a bit of fine tuning. Keep it up, scout!

Fitted is good, just not really fitted. The legs should really fit like a pair of slighly loose fitting jeans. The elastic strap on the thigh should be stitched with a bit of tension in the elastic so that when worn, it actually gathers what little slack there is on the thigh.

That's a horrible knockoff of a KS holster. Lots of trimming to get anything holster-like for that thing.