Rick Lyon - Stormtrooper Page 4

NOTE: it's almost impossible for one person to assemble an armor kit alone. There are critical steps in the process where fit has to be customized, and you just can't wear it and hold it and mark it all by yourself. So get a good friend who is craft-capable to help you out, and treat them well for helping - feed them, buy them drinks, etc.

The instructions that come with the Armor F/X kit leave ALOT to be desired. The prescribed methodology for putting the suit together, is, in fact, misguided. The original instructions want you to put all the pieces together using sticky-back velcro, which is provided with the kit. Don't do that! The consumer strength velcro included will not stay put. Also, you are instructed to put the hook part of the velcro facing in, and the fuzzy loop part facing out - that is a REALLY bad idea! The hook will snag the living daylights out of whatever black bodysuit you wear under the armor, and potentially abrade you, too. So any velcro that you do use should be put with the hook part facing out, and the fuzzy loop part facing towards you. More about velcro later (it does have it's place).

If you have a slender to moderate build, you'll want to glue most of the pieces together. This makes them sturdier, and look much neater. You'll want to use the ABS glue that comes with the kit. WARNING: ABS glue is not easy to work with. It is extremely toxic - always use with adequate ventilation and while wearing a respirator. Also, the way it works is to dissolve the ABS plastic a bit, and actually create a weld between the pieces when they're pressed together. It starts to dissolve the ABS on contact, so you have to work quickly to get the pieces together before the surface of the glue starts setting up and refuses to stick. It's also critical that you not get any extra glue on any exterior surface of the armor, otherwise you'll get a permanent scar in the plastic which is very difficult to buff out.

When I have a chance, I will post a page or two about each section of the armor, and discuss how I customized each to my own preferences. Sorry, this probably won't be anytime too soon, as my professional schedule is nuts right now.