Archive for June, 2008


Tip of the Day – How To Remove Devcon Plastic Weld

This tip will only work if you want to completely remove Devcon Plastic Weld from an armor part, say as if you had catastrophic failure in gluing your shins…)

If you don’t mind removing all the glue from the piece you can throw it in the freezer for a few hours. After that flex it a little and the glue should pop off with a little effort.

Be careful, as I haven’t tested this myself and remember the cold can make your ABS armor fragile.

Armor Work, Painting

Progress Report 6/10/08

I was able to get a few hours in on the TK armor on Sunday afternoon at least until I got sick of being soggy from the humidity. YUCK!

I sanded down the two halves of the 02 tank and painted it with another coat of gray. This will be the last coat regardless and will move onto trimming the halves and assembling the tube.

I was also able to assemble the two halves of the bicep armor with little difficulty, although I did have to attempt to reshape the inner halves of the biceps as they are misshaped and don’t line up to the outer half well.

To fix that, i brought down my hair dryer to heat up the piece to reshape it. Let me tell you, this method sucks. Its time consuming and generally just doesn’t seem to work, even after spending five minutes warming up the area.

On the left bicep, I was able to heat it up and let the glue hold the warped area in place, but the right one, I had to warm it up, Velcro it together and then hold it in the clamp. This hasn’t worked too well so far but I’ve found that leaving the pieces clamped for a few days is helping fix the warped area.

I also tried my hand at the first shin piece and had a catastrophic failure with gluing. I was unable to keep the middle part of seam to glue together even with holding by hand. Luckily I was able to tear the two halves apart with very minimal damage. I am now going to have to work on sanding off as much of the glue residue as possible and retry.

I have seen some good talk about computer hard drive magnets being used to hold the middle together where it can’t be clamped. Thankfully, I have several old computers at work, waiting to be recycled so I pulled the hard drives apart yesterday and will try again.

References, Tips, Tools

Tips – Mr. Clean Magic Erasers Rock!

After reading up on the FISD about what kind of cleaner that is safe to use on the ABS plastic the armor is made out of, I found a bunch of recommendations for Mr. Clean Magic Erasers.

I needed to clean off newsprint smudges and some tape residue, so I popped by Target and ended up getting the Target brand version because it was $1.99 on sale for a four pack which was cheaper than the 2 pack of Mr. Clean. (Make sure you get the regular sponges and not the other heavier duty ones.)

Anyways, I have to say, this thing totally worked. It cleaned everything off the armor with little work, just make sure you have a towel to dry off the pieces after you’re done.

I wholly recommend getting these and its probably a god idea to keep one in your repair kit once you’re ready for full time trooping.

Armor Work, Painting

Neckseal Came!

Yup you read it right. It came from the UK in about four days. WAY quicker than the resin Hasbro mod kit did.

Did a test fit, it fits loose but you’d never know it from looking at it. The lining is the same satin material as the bib and its comfortable. My only two gripes are that the bib is really just too long and that straps on the bib would be better replaced with elastic and Velcro. Also the satin inside the neck is a little loose like theres too much fabric and likes to poke out the top of the neckseal. Its not too bad though and it can always been tucked back in.

I forgot my camera at work last night so I’ll have to get pictures tonight so you can see the finished product.

Also I pulled the masking off my helmet last night. The paint job on the inside came out well but the outside needs to be cleaned up. It has newspaper ink smudges all over, but that should clean up rather easily.

I hope.

Armor Work, Painting

Day 4 Rundown

Received my rubber t-tracks for replacing the rails on the Hasbro blaster on Friday! YAY! These will need to be shortened to fit the shorter Hasbro barrel but they are accurate to the screen used blaster. That will happen later when I get ready to finish the blaster.

So onto the armor work. Started with doing the bracers. I followed pretty to the letter the directions from the bracer tutorial from Dave’s Garage. The two parts to that can be found here:

Part One
Part Two

Basically, I started by sanding the areas that would either have Velcro attached or glued. This takes the “shine” off the ABS plastic and makes the glue attach better.

Next, I attached the soft side of the Velcro to the outer piece of the armor. First off, you ALWAYS want the soft side pointed towards you (and your undersuit) as the plastic side will tear it up. Also doing this part first is best because having the two sides of Velcro done first can make gluing more difficult and it is easier to attach the piece of Velcro here now because its easier to access than after gluing.

After doing that, I taped the heck out of the Velcro side of the bracer to support the bracer for gluing. Then I clamped the two ends of the glue side to mesh the two sides together and then ran a piece of tape flush across the edge of the seam to mask any glue that might squeeze out once the bracer is glued and clamped.

Once that was done, I pulled out the Plastic Weld, squeezed out some into the plastic bubble from the package and mixed it quickly using a wooden dowel. Set the timer for 4 minutes and went to work and applied the plastic welder with the wooden dowel and the aligned the top edge and clamped while holding the center together with my hands for a few minutes for extra support.

Once the timer went off, I took the clamps off and removed the masking tape piece and cleaned up and excess glue with my Xacto knife.

Once that was done, I trimmed off a piece of the plastic side of the Velcro and attached it and then Velcroed the two sides together.

Repeated for the other bracer.

After that, I spray painted the insides of the bucket parts after double checking the masking tape to make sure that no gaps appeared in the masking. I used the satin black Krylon I bought for the blaster to spraypaint.

I stopped there because I started to get a lot of dandelions “cotton” seeds blowing into the garage that I didn’t want stuck in the paint.

Next up, I will probably continue onto the biceps and then move onto the leg armor. Also the gray parts are in need of another sanding and coat of paint as well as the the 02 tank still needs to be trimmed up to fit the end caps.

Armor Work, Painting

Day 4 Bracers And Painting The Bucket

Armor Work, Painting, Setup

Day 3 Rundown (Yeah its late.)

Haven’t had time to update the site with the work I did on Thursday, so here it is.

Decided to do a test fit of the bucket to see how everything fits. Got everything together and I have two issues. One, the edges of the front and back need to be trimmed for a better fit. You can see in the pictures where the edges don’t fit properly and will need to be cleaned up. And two, the ear pieces have HUGE gaps where they cover the seams on the tubes. I’m researching how I want to deal with fixing that.

Next, I masked the outside of the bucket pieces. You can see in the pictures how I did that using masking tape and newspaper. Very easy. You can also see that I cut out the eyes in the masking and then taped down the eyes. This is done to seal the eyes to keep overspray from getting into the masking and onto the face of the mask.

Armor Work, Painting, Photo Gallery, Setup

Day 3 Test Fitting The Bucket And Masking