I'll hang the thighs off a belt and braces. What else? I'll make the new torso separate from the thighs. Six hours standing is no joke any more and it's nice to be able to take the weight off. The butt plate is made super thick, in one continuous layout of cloth, so there is no chance of it breaking when you sit down. Even then they will need some padding and also some of the back of the knee removed. The db files are too slim fitting and I pepped several versions before I got close. The knee plate had to be supported out in front of the knee on a piece of thick rubber, because it was seriously painful on the kneecap otherwise.

Also, the lower sides help the calf become self-aligning. The calves were a real problem until I cut out a panel in the lower inner calf and secured it with small zip ties. Pretty much every piece is made overly long so it can be trimmed to length to suit.įibreglass suits are totally inflexible, and armour bite is a lot worse than with vacformed plastic. The shoulders and arms also needed tweaking. I found that I needed to lengthen the calves and thighs, and widen the torso pieces. My suit is partly based on a mix of my files and some heavily modified dung0beetle files. The fibreglass is a lot heavier than plastic, and as I'll be 65 next month, I'll be doing shorter stints from now on. I have done over twenty troops now, and completed two 11 km walks. Actually, I never really expected to get it to this stage - it's a lot of work, with pieces being pepped and re-pepped up to a dozen times each. Not nearly screen accurate, I know, but my version is that it's for the taller and more bulky trooper. It's still a work in progress and I the arms and thighs are vacformed plastic, but I've glassed all the remainder - just needs finishing and strapping. Here's a photo of my Gravel Trooper suit at my mum's 90th birthday last year. I thought it was about time I assembled my files and shared some progress pics and problems I had to overcome.

Star wars pepakura files