Great Lakes Garrison & Base

I bought the least expensive cordless Dremmel. Went cordless so had more freedom, like using outside. It can make a mess... Got it at Lowes I think. $60 maybe? Can't remember for sure.

Just get an assortment of tips. The one I used the most is the round one that allows you to replace the sandpaper. I have AP armor and the score and snap method is how most of my initial cuts were made, followed by dremmel.

Any dremmel will do. The cordless one sounds like it would have been nice to have.

Nothing like the freshly dremmeled armor and E6000.

Flash wrote: Nothing like the freshly dremmeled armor and E6000.

my wife hates that smell. starts griping every time i start using it.

Be glad that Devcon plastic welder isn't the glue of choice anymore. That stuff is crazy smelly.

I went with a corded variable speed Dremel and a flex shaft attachment(http://www.dremel.com/en-us/Attachments ... pid=225-01) for easier cutting. I hate to have to charge any tool before I use it and have to worry that I 'll have enough juice to finish the job. The only cordless tool I own is a drill and I have 4 batteries for it just in case.

Like Flash said, make sure you get an assortment of tips. I really like the diamond cutting blade. Terrell had told me once that they have those blades for cheap at Harbor Freight, but they are usually sold out at my local store. I ended up with the Dremel branded one which was a lot more expensive but worth it.

OK, I am a couple weeks away from getting the armor, and have everything else except the gloves and decals for the helmet. Anyone have a recommendation for where to get the decals for the ESB trooper helmet?

http://stores.ebay.com/Trooperbay-Costu ... 34.c0.m322

Make sure you get the ESB version. Has different number of tube stripes. Also make sure ATA helmet is listed as compatible. Most likely is.

Awesome - you rock!! Thanks so much

Gloves. I assume they need to be past wrist length, according to the pics I've seen in other postings. Any suggestions? Rubber or leather? Other material? Trooper e-bay again?

Go to Amazon and search for nomex flight gloves. Mid to upper $20's.

Congrats on your build! You are gonna have a blast. I built a CAP set of armor a few yrs ago and it was pretty darn rewarding
A couple of things I'd suggest you get beyond what's been mentioned so far:
For the build process in general, I'd get the following stuff (my personal pref's here). See the build thread link below to see all this stuff in use...

Magcraft Super Strong Magnets NSN0642/N40 1/2" dia x .375"th
Small, strong scissors to trim plastic
Xacto knife w/ #11 blades for trimming
PVC glue
Wet-dry sandpaper
400 grit 3M sanding cloths
Band aids--keep them close by
Novus #2 fine scratch remover
E6000 adhesive
duct tape or painters tape
Set of small and medium clamps/ vise grips
Hillman aluminum 3/16" threaded post screws

My CAP build thread: http://s156.photobucket.com/albums/t28/ ... ?start=240
PW: buildyourown

Has anyone mentioned a canvas belt yet?
For gloves, I like these http://www.amazon.com/Special-Forces-Ta ... 735&sr=8-2
Miles of strapping and velcro, too!

crow wrote: Band aids--keep them close by

Yep. For sure...

Oh...and if you need some mesh for your bucket frown, don't buy it. I've got 2 diff types I can send you for the cost of postage...

OK, I have my armor!!! It was equally exciting and terrifying at the same time to open it. I am a teacher, so I have the entire Spring Break in April to work on it. I got the ATA armor. Does anyone know of a video tutorial I could watch? I am scouring the sites for it now, but any help would be appreciated.

Here is a great tutorial.
http://www.flickr.com/photos/stukatroop ... 721766632/

Not sure if there are any video tutorials out there for armor.

I'm back! OK, maybe nobody noticed or cared, but I was off these forums for a while. I admit, I got a bit scared of starting to build my ESB trooper armor, and put it on hold. I am not a handy man, and I was worried I was going to ruin it. However, I am starting to build the arms, and I have a question if anyone is still reading these: What does it mean for the forearms that no return edge is allowed on the inside of the front of the forearm?

It means don't leave a lip on the end. Most places you will leave a lip as it gives the illusion of thickness to the armor.

OK, I think I get it. So, that means the armor should be straight from the elbow down to the wrist, and it doesn't curl underneath? Kind of like a tube?

Obi-Ron wrote:OK, I think I get it. So, that means the armor should be straight from the elbow down to the wrist, and it doesn't curl underneath? Kind of like a tube?

Yes. But only the wrist side. That most likely was a necessity since it would be near impossible to slide your hand through the wrist hole if you leave a return edge. Leave it on the elbow side though or you will have too much open space.

Question about the snaps. Is it best to use industrial snaps (I know they're harder to snap on and off, but would provide more security), or do any of you Troopers use regular snaps and have had no problems with them?