Under Construction

 

Construction List

The whole costume has cost about $150 so far:

I am still working on the wrist communicator and helmet modifications.


HELMET

This is a Don Post collectors helmet which I painted the silver parts with an airbrush. I also cut out the teeth, drilled holes for the hoses and replaced the lenses with Vaderpainter lenses since the standard ones are so distorted. I also used polishing compound and then waxed the helmet. I am planning on adding electronics for a voice amp and radio.

 


The lenses I used to replace the standard ones. Click here to see the difference in clarity. The don't fit perfectly because they were designed for the Classic Action helmet but they are pretty close. I also made the eyholes bigger, the right hole is the unmodified size. This has greatly improved the field of view.

ARMOR

The chest armor is made from scrap 1/8" aluminum. I cut out a cardboard template that fit me. I cut the plates out with a shear but a jigsaw or nibbler could also be used. The plates were formed with a ball peen hammer on a dished out stump. You could also do some bending with a vise. The back is also made from aluminum with a piece of plywood fiberglassed on for the box. I used black epoxy appliance paint for the armor and chest box. The two plates are connected with strips of a rubber auto floor mat which are bolted to the shoulders.

LIFE SUPPORT UNIT

I used the Bubbas Barnyard plan for the chestbox.
The chest box is made of MDF (wood) and plexiglas. I also used ABS and PVC pipe for some parts. The buttons are made of sheet styrene. I used a 3 rocker wall switch and 2 indicator lights also. On the sides of the ABS pipe at the bottom are two RC car gears which were screwed to ABS test plugs that close off the pipe. The pipe is a battery compartment for the electronics.
I have installed two fans inside the box that push fresh air through the hoses into the helmet. I am also going to set up a voice amp and communication radio. Click here to see a parts diagram.

ACCESSORIES

The boots are East German officer boots sometimes available from Sportsmans Guide or other surplus stores. I made the belt and holster from scratch using leather and stainless steel. The gun is a Denix mauser replica witha machined muzzle.