Sgt.Bilko

More progress. Does anyone install the chin strap? Not mentioned in the CRL. Sent from my iPhone using Tapatalk

Appliance white looks really good on the helmet. This weekend will assemble the helmet. Long awaited moment. Sent from my iPhone using Tapatalk

Yes sir. All along the inside. Then I applied plastic weld for a bit of belt and suspenders add-on. Afterwards, I applied bondo filler. Sanded all that down and finished off with glazing spot putty (inside too). So inside the helmet, I covered the strips with Bondo for aesthetics. Helmet is solid. WIP pic. Paint still drying. Sent from my iPhone using Tapatalk

Duplicate post removed

Sanded down the helmet and painted the inside flat black to get started. Will move to the exterior and paint with Rustoleum appliance white. Sent from my iPhone using Tapatalk

I suppose you can heat up the strips to bend to the contour. I did not and chose to cut smaller contour pieces. See the photo. Sent from my iPhone using Tapatalk

Should be fine with flex of the helmet. What about the trapezoid measurement on back? If you are close on both, given your gaps, Chopper is correct it's time to glue the halves together and focus on closing the gaps. What seems odd to is the gap with the pencil lines. Are those your pencil lines or RS? My RS pencil lines were good enough to get me to the ball park and switch to sanding down for fit.

Helmet bondo applied, sanded and painted primer on. Finishing touches with bondo glaze. Sent from my iPhone using Tapatalk

Hi, Just finished piecing together my RS helmet. To make sure you have or have not cut too much, confirm these measurements. Get the ends to line up with these, tape the ends and work toward the middle section, trimming as need be. Sent from my iPhone using Tapatalk

Ok, with some guidance from Rob at RS, I was able to complete the helmet together and complete the mask construction. Will be applying Bondo, sanding and paint prep this weekend. For me the toughest part was trimming the helmet halves and final alignment before gluing. Rob’s guidance (for those stuck in this similar position) was: “Looking good. OK, best way to put this is, force it! The plastic will flex and needs a little manipulation to meet correctly. Not much, but you may find you need to trim a touch out of the “flat” area on the top. That’s fine, it’s not as perfect a half and half as you would assume. Try to line up your points at the back and the front then assess what the top wants to do. You should find you can get it to do what you want this way.”

Finding putting the helmet halves together a bit difficult. The brim of the RS helmet left side is a bit wider than the right (measurement confirms). Has anyone encountered this? What am I not doing here? Thanks! Sent from my iPhone using Tapatalk

Helmet Build. Followed the mold and pencil marks. Ear check. More? Too much? Sent from my iPhone using Tapatalk

Strapping done for now, a new box came today! Sent from my iPhone using Tapatalk

Hi @Chopper, any feedback on this? Or should I reach out to my local GML?

Redid the tank support following @Chopper ’s How to make Armor wearable guide. The tank is extremely secure, but easily removable. Sent from my iPhone using Tapatalk

Boot holster, blouser and rivets (with ABS supports) installed. Sent from my iPhone using Tapatalk

20mm outside stitching. Sent from my iPhone using Tapatalk

Whilst the ABS paste is drying, moving on to the boots. I ordered mine through Imperial Boots (Keep Trooping), as they were one of the approved vendors. The boot back is secured with a 20mm hook and loop fastener. The CRL states it should be 25mm. Does this need to be extended? If so, what have others done?

Paste creation, application. Scraps from the armor, so should be a match. Setting overnight. Sent from my iPhone using Tapatalk

Turn those knees around? Nah, my knees are already pointing towards the future—a future where The Mandalorian meets Endor’s speed demons. Why settle for ROTJ when I can rock a biker scout helmet with enough swagger to make Din Djarin jealous? I’m not just blending in with ferns and Ewoks—I’m cruising through hyperspace with a blaster in one hand and Grogu’s snack pack in the other. This isn’t just a costume—it’s the way. Sent from my iPhone using Tapatalk

Hi Chopper, as always thanks for the catch before I get too far. I was blindly following Mickeys video and totally missed this. Looks like I’ll be making some ABS paste. It’s been a minute, but should be able to get that done. Would have needed to do it anyway, because MonCals armor had a large hole cut out at the tank bottom. Sent from my iPhone using Tapatalk

Getting the tank mounted. Used neodymium magnets with strapping. Similar setup as my TK. Parachute clip is on its way, then the knot goes away. Sent from my iPhone using Tapatalk

Sewing the suit. Armor attachment with strapping and Velcro. Moving to the chest side straps and back tank. RS Props helmet is on its way! Sent from my iPhone using Tapatalk

Chest workout. Snaps and straps. Sent from my iPhone using Tapatalk

Continuing the strapping and sewing. Is this gap worth closing? I’m ready to trim to fit closer to the body before adding strapping. Sent from my iPhone using Tapatalk