dcx13

There’s nothing wrong with using PLA, it’s just a matter of durability. PLA is plenty good for making all the parts, but PETG is a bit more robust when it comes to heat - less likely to warp if it’s left in the car, for example. I’m using Polymaker “CosPLA” which is a bit more heat resistant & much easier to sand - they designed it specially with cosplayers in mind. So far so good. You can print with whatever you feel like is best for your project, as evidenced by the Armory Shop kit’s material, which is really fragile, and the reason I am now rebuilding the entire costume with a mix of TPU, PLA, and vac-formed parts from Walt’s Trooper Factory.

I have a full Armory Shop PT and as good as it looks in photos, I can say that the material is very brittle & the paint cracks just thinking about it. The helmet is absolutely stunning though (please ignore the 2 chipped fins, it got chipped in transit). I am almost in the same boat as you are, as I now need to rebuild 99% of the kit, and have found that WTF (Walt's Trooper Factory) does a PT kit as well. Since Walt's TKs are well known, and his availability of product is good & he is always quick to answer any questions, I'll be going with one of his PTs. He does much of his contact through FB and the WTF FB group. I also have @MrPoopie's files, and they are extremely well thought out & organized. I think using a combo of the printed file parts & the WTF kit you could have a very robust and easy to live with/comfortable PT when finished.

I get the whole CRL is what we go by, but I'm asking the cap question in terms of situations where wearing a helmet, aside from putting on for personal pics, is non-negotiable. I'm looking specifically at events like ones on Disney properties, Oogie Boogie, Disney After Dark events around May 4th, etc. From the park costume guidelines: "For Guests Ages 14 and Older... Headwear may be worn as long as it does not cover the face. Masks of any kind may not be worn, except for medical purposes." I spoke with a few of the security guards while I was there last month, and they all said essentially the same thing as the rules state, with the caveat that they understand the SW fan experience, and are completely fine with popping ye olde bucket on to take pics here 'n there, but wearing it around will lead to problems. Like I said in my original post, I just figured the cap would be a good way of maintaining an "in uniform" appearance when certain situations don't allow for helmets.

I definitely 2nd you on the Alpinestars assessment. In the top middle pic, you can clearly see the a-star logo on the sole of the boot. White isn't a hugely sought after color in moto boots, so you may have good luck finding some on closeout/clearance. Also, Alpinestars' boots are generally evolutionary models, so if it's "X" specific model, there may be near identical features on a previous, or lower spec version.

2kg of white TPU ordered. The files are amazing!! The checklist pdf is a nice touch too!

The box has arrived!! As expected, a few of the more fragile bits are broken (thanks USPS), but everything else is mainly intact & serviceable. The helmet, is absolutely unscathed! I'll get everything laid out & do an inventory of what needs repairing over the weekend. Has anyone printed some of the more flex-prone pieces out of TPU, or similar materials? Thoughts? Guess it's time to get the files@MrPoopiewhipped up.

I've got a pair of Anycubic Kobra Max printers primed & ready (they're currently churning out parts for my Death Watch mando) . I've also got @MrPoopie files bookmarked as well.

Recently took ownership of a complete Armory Shop Patrol Trooper kit. Previous owners were relatively close in size to me, so soft parts should only need some minor tailoring. The hard parts, on the other hand, will need work. When I got it from @vbechtol, he was up front about what needed to be done & sent a few photos detailing the trouble spots. None of it looks too terrible, but my main concern now is the rarity of these kits, and the ability to get replacement pieces if needed. So, for now, I patiently await for the mail to be delivered, and see what I'll be working with. Pics of the damaged spots (prior to shipping).

If USPS is, A. showing accurate tracking info; B. hasn't damaged it beyond repair, it should be arriving today & I'll get some photos going over the weekend.

I’m the 3rd owner (to the best of my knowledge) of a complete Armory Shop kit, but it will need some work to bring it back to approvable condition. Is there a source, or does anyone have assembly info, etc, for the kit? I’m pretty sure I can figure it all out, but I’m a firm believer in RTFM when it comes to rebuilds/repairs. Since these things are no longer in production, I don’t want to chance damaging it further.

What are everyone's thoughts on having a black officer's cap as part of the kit when situations do not allow for a helmet; i.e. Disney/public events where you can attend in costume, but are not allowed to have your face covered. The helmet would be along for the ride, but the cap would take its place in terms of staying "in uniform." I was also thinking of it as an easy way to stay in character when tending to a group's table/convention space, taking a break at an event but still in public view, etc.

Do you have a link to Spudly’s build? Did a search for “Spudly” but it just keeps looping me back here. I’ve got my 850AW stuff in transit now.