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Posted (edited)

I also got a mannequin to make building the uniform much easier. So far so good, got the front of the shirt finished and one of the sleeves (just need to hem the wrist to the right length). The striped section is stretchy, so it will be pulled to match the width of the armor once it's all stitched together on the back and sides. (The armor in the photo is for demo only and wider than the actual chest piece is)20250208_195301.thumb.jpg.8bbfaabd7ae69cfef94f87cbf9ece8ae.jpg20250208_153206.thumb.jpg.64dbc5b1e45d640c225d01e47738f7bf.jpg

 

And the full mask and custom half mask have been finished and should be here this week.  Screenshot_20250207-075808_Etsy.thumb.jpg.4aee3c337412a7b57b9acab3abc54779.jpg 

Edited by GrandMoffKK
  • Like 1
Posted

Here's the final versions of the updated armor that were painted and clear coated in semi-gloss today. From a distance everything just looks nice and shiny, but up close you can see everything has that nice uniform ballistic metal/SAPI plate look. I think it looks more believable as actual armor than the smooth finish did. So I definitely like the look much better, and I'm finally satisfied with the end result.

 

Only thing left for these parts is just to add a couple spots of weathering on the bracers and hand guards, and then add the lights to panel on the left bracer.

 

20250209_165742.thumb.jpg.2f419db68c7c1a4493b63114431d5e84.jpg20250209_165617.thumb.jpg.8513610db340e3b573b6940ec13c519e.jpg20250209_161814.thumb.jpg.6b4c1deb0dc695631a23f5f89058f4c3.jpg

 

Here's the lineup I used for the armor pieces, used in order from left to right:

20250209_172554.thumb.jpg.3874ca29ac803d4182abd9da2177927b.jpg

 

The chest piece was sanded and primed today, so it will get some more sanding tomorrow and if all goes well, then I'll start applying the black semi-gloss trim paint.  

20250209_162713.thumb.jpg.da3ddc60711a97600a15ce2fcdaea399.jpg

 

And again, this is the look I'm trying to create by adding texture to the armor:

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Screenshot_20250208-201343_Gallery.thumb.jpg.52107991acf081abb35af7b6bc33a650.jpg

 

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Also got the base layer paint on the lightsaber. It's metallic black stainless, but it reflects a lot of light so it looks lighter in the photo than it actually is. I'll be hand-painting the rest of the details such as the grip and emitters, and then I'll be adding in the red lights/magnet inserts into the center trays on each side. Then it will just be an ornament on the back of the chest armor like in the show. 

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  • Like 2
Posted (edited)

Got the lightsaber finished, complete with red magnets to look like lights but that serve to hang the lightsaber off the back of the chest armor. CRL wants it mainly black, so I left the main ring in black stainless color and just painted some of the details to match the version in Rebels a little more. 

 

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Screenshot_20250210-102021_Gallery.thumb.jpg.90894c9e65220ba2a8ab362bfff78c3b.jpg

 

20250216_144159.thumb.jpg.e657bcb01eefdf89b646cc231cecc45c.jpg

 

And added the lights (CR2032 powered LEDs) and some weathering on the left bracer to match the show:

20250214_213004.thumb.jpg.bef2837ee8f2b829945dd78328c4d837.jpg

 

20250214_213410.thumb.jpg.5973d7dc974c74bf41380ba80517ca23.jpg

Edited by GrandMoffKK
  • Like 1
Posted (edited)

Finished the chestpiece and added a AAA powered LED strip behind the red lens. I used on of the LED strips they use for backlighting eyes in masks like Iron Man and just rewired it to be one like instead of two in parallel. 

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Finally got everything done 🎉20250221_131149.thumb.jpg.f92f803f82fca00019c57c0e9d3c21ed.jpg20250221_131212.jpg.c91ef3ba8ff0c6cd9243fac7cd7f4df3.jpg2025-02-21-16-14-14-353.jpg.40d0ea4d5c164fba99be29f0edb94983.jpg

Edited by GrandMoffKK
  • Like 2
Posted (edited)

I also ended up adding snaps and velco to hold all the armor in place. I added reinforced snaps to the uniform so I can snap in a long piece of Velcro (loops) for the armor piece, which has the hooks part of the Velcro glued inside it. Let's me dress myself pretty easily without worrying about pieces falling off. I'm using Gorilla tape for now instead of gluing the Velcro while I'm working on the best placement for them.

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I also have a custom set of teeth being built to more exactly match his upper and lower teeth, so I'll share those too when they arrive. 20250221_075916.thumb.jpg.66dceadfdc53912fd624fc4073facf9f.jpg

 

*Update: here's the custom teeth I had made for him, now on their way from Belgium 

Screenshot_20250303_145951_Etsy.thumb.jpg.c0d314fdfb9121a272c4e664151e0a7b.jpg

Edited by GrandMoffKK
Posted

Also - happy to share the STL files for the boot rings, ear covers and belt buckle with belt loops since I made those from scratch myself. 

Posted

I thoroughly enjoyed your WIP! I would love to see more in process DIY pictures. Absolutely awesome work and an outstanding final product! Looking forward to your next project! Blue Skies!

  • Like 1
Posted

Thank you! 🥰

I have hundreds of photos (6 months worth, lol), so happy to share whatever you might be interested in. 

Posted

Got the new custom teeth in and made a few updates to the silicone mask to make the tattoos a deeper red and make it fit better around the mouth. Still looking to make improvements on the whole costume as I get more experience, but it was good enough for approval thankfully so that I can finally get out there and start trooping. 🎉 

(and yes, I still have to learn how to take better pictures... sorry)

 

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Whipped up a little hooded cloak to use to cover myself while sneaking through parking lots and such heading in and out of events and couldn't resist doing a hooded Sith-esque pose in homage to GI's intro in the comics. And the photo allows for a better shot of the new teeth and the mask upgrades, too. 

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