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zv288bot's Rebel's Biker Scout Build Thread


Zv288bot

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So as I did some test runs to help make final adjustments for a better fit, I need this bund to be held in place. If I don’t, I’m gonna end up looking like those scouts in the Mandalorian LOL.

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I’m doing a lot of these measurement myself while wearing it looking in a mirror. Definitely not the easiest thing to do. The blue tape if basically marking for me where the chest plate ends.


I decided I would add 2 Line 24 snaps to the front of the bund that would attach to the inside of the chest plate.

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As used in other parts of this build and following the success from my TK build. I am using nylon webbing to secure the other side of the snap.

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I will suit up and hopefully mark the area so I can glue the nylon webbing on the chest plate.


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Getting down to some minor fit “clean up” items.


So here are the snaps after I got the placement as close as I could get it. I used E6000 to glue the nylon webbing to the interior of the chest plate. Using some magnets to hold them in place until the glue dries.


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Again, while just looking over the fit,I realized the shoulder bells where sitting too close to the chest armor especially when I compared it to reference images. So I added a block of EVA foam to raise the shoulder bell. I am securing this with E6000 as well.

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I also realized wondering around the house that I started to feel some discomfort with the knee armor/plates. The bottom of the plate started to dig into the underneath of my knee when standing up. I’m just adding some more EVA for comfort.

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I also glued all of the belt boxes in place. Again, just a dab of E6000 behind every elastic band.

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I am also adding a piece of Velcro to the back of the belt. This will be we’re the strap for my cod piece will attach.

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And lastly, I cut some EVA foam (floor mats) strips to use to reinforce the bottom and side walls of the pouches. I wanted to keep them as “open” as possible to maybe use?

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I am down to just the helmet and blaster holster. Just need some warmer weather.


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This is really coming along. Great tweaks and I’m digging the snaps to secure the bund to the chest armor. Velcro is such a staple here for builds that I for one often forget that there’s other options. Great idea and reminder! I might do the same for my JFO bund and armor. Thanks!!!

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So I got some moments in 50 degree weather to get outside and and do some bondo and sand and fill and bondo and sand fill and sand and fill and…


So I applied a liberal amount of E6000 to both sides of the mask to mount the visor before I do any more finishing work on the visor.

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And flexing the visor cracked the bondo. So glad this happened now.

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I’ll go back and sand and fill and add a layer of Devcon plastic welder.


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So I sanded the area down and applied a layer of Devcon. This stuff smells so bad. Make sure you do it in a ventilated area, wow.


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Under the visor, I had the piece of sign and applied bondo to smooth out the sides.

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I’ve moved into glazing & spot putty. I will hopefully lay another coat of primer and see what areas will need attention after that.

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So excited! It looks like a helmet!

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Great work! Adding the scrap piece of sign to reinforce the seam on the underside of the visor should do the trick! Nice!

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Looks great there! And the part that you was asking fr what is it, is chin cup for the helmet. 

Looking at every other build thread on here I think it’s a part that got dropped in the box and doesn’t actually belong to the kit. I didn’t reach out to Walt to ask, honestly I literally just tossed it yesterday. I think it was a knee plate for one of those tank drivers.

Thanks for the comment!


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Still working on the helmet. Weather is cold with high humidity and even snow last week. My other issue is when I flex the visor, I get a small “micro” crack at the front of the visor where the seams meet. Obviously, I don’t want to spend the time painting and finishing it only to have a seam pop up. I’m just going to keep on filling and sanding until I feel confident it won’t be an issue.


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Re: seam cracks.

Looking at your earlier helmet construction photos, do you have a reinforcement plate underneath where you've joined the seams? It doesn't look like you do?

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Re: seam cracks.
Looking at your earlier helmet construction photos, do you have a reinforcement plate underneath where you've joined the seams? It doesn't look like you do?

Hi Chopper. I did add a piece of plastic sign that I had laying around. It is on the thicker side. Wonder if that is adding to some flex.



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Not sure that there's much you can do now, but plastic sign material is thin and pretty flexy, which makes it easy to cut. It also makes it easy to bend. I agree that's prob the reason you're getting the micro cracks -- because you're getting slight bends in the plastic, which is cracking the bondo/paint.

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Ok so I laid a coat of white primer. I did it in the dark so excuse the runs. Figure it’s getting sanded again so no big deal.

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This is where the seam is.


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Runs are gross but I am feeling better overall.


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I had weather over 50 degrees today! I also had the day off! The spray paint gods smiled down upon me! Success! Based off @chopper's recommendation I sprayed these parts down with Rustoleum Appliance Epoxy paint. It’s gonna take 24 hrs for full dry and then hopefully assembly!!

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Seem on the boot holster.

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Boot plate.

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Sooooo close! Maybe pictures submitted this week!?


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I read various posts on the boards about the pros and cons of fans. I have them in my other 2 costumes. I’m putting them in this one as well. Here is a set I wired up.

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I am hoping that I will be able to install them in the front forehead area pointing down. Once I play around I’ll update where I landed.


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Ok, here are some helmet assembly pics. I did run into some issues I was not expecting.


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So the CRL says the circles need to be round. 100% agree. The decals I got apparently felt otherwise. They are pretty oval in shape. I just created the design myself and cut a new decal.

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I added the front speaker/aerator with some E6000 glue. The nose piece is a decal provided by Walt.

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Soooo, I did get the decal set for this but can’t for the life of me find it. Then I figured I had luck making the red one. Just do this one as well. Well, that’s a not so much because taking into account the curvature of the helmet while trying to keep straight lines was quite the challenge. Not 100% satisfied with the look. I wound up applying each piece individually redoing a few of them several times. It’s all about the angle. At some angles it looks good and at others not so much.



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I cut a piece of welders face shield that I had laying around from my daughters Mando build. I had the right amount. I pressed it in and traced the outer edge with a sharpie. Once I cut it to size I got glued it in on the top and sides.

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As with the ROTJ scout helmet, getting the "bar code" to align right is nigh impossible. Basically, just pick a parallel line on the helmet to align with and stick with that one -- regardless of how it may look from other viewing angles.

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3D printed some "washers" to sit in between the visor and helmet. I could have gone out and purchased some, but it was late, and it only took 10 mins to print. My main reason for adding these is the chicago screws that I am using are just a smidge to long. I am hoping these washers will fill in the gap.

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Oh yeah!

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I got the fan installed. For the couple of minutes, I had the helmet on I did manage to fog up the lense. Here's a couple of shots.

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I lined the bottom portion of the helmet with black hockey stick tape to give it that dark appearance when looking in.

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Ok, last pics before I suit up.

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So, I ran into some issues when I was doing final assembly on the helmet. Two things really, one, the epoxy on the gray visor discs gave way. I went back and applied a good amount of E6000 and they are glued in place and feel firm. The second issue was once I installed the visor. I could not close or open the front of the helmet. At first, I thought it was the glue, after cutting some of the excess away and still not working. I took a closer look and the only thing I could figure out was, for whatever reason, the extra material thickness added by the visor was enough for the top of the helmet to hang up on when trying to open or close the helmet. I am assuming at this point this could only be from mounting the face plate to the visor too far back. Currently my face mask lines up flush with the back of the visor. I am wondering if it needed to move forward a 1/4 of an inch or so.

At this point, not much I could do, so decided the easiest thing would be to move the visor forward, away from the helmet itself. I was able to do this by drilling new mounting holes in front of the old/original holes. It definitely accomplished the desired effect. The only downside from this is I now have this gap between the visor and the helmet. While I am not expecting most to notice it does let a bunch of light into the helmet. I may see about filling the gap with some flexiable craft foam down the road.

 

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Alrighty, here are my submission pictures. I know we need to wait on elections to wrap up but figured I should just get them out of the way. 

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and the inspiration to do this -

 

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Wish me luck and thanks for cheering me on! Can't wait to be officially part of this detachment! It's a pretty cool bunch!

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