TX : Shadow Stormtrooper Rebuild

The 501st Costume Reference guide can be viewed here :

http://www.501st.com/databank/Costuming:TX_shadow_stormtrooper

I've recently purchased an old set of TX armour which was in need of desperate repair. I got it at a great price, but at the cost of a lot of time and work. This page is the work in progress of how I went about re-sizing, refinishing, and rebuilding the set of armour. Even though I will be working on multiple pieces at the same time, and they will be completed at different times - I will be updating each section from start to finish so its a linear progress report.

Lets begin with the helmet!

 The helmet had orange-peel and crackling paint, loose ears, saggy brow, lots of scratches.

The helmet had orange-peel and crackling paint, loose ears, saggy brow, lots of scratches.

 Ears have large gaps.

Ears have large gaps.

 Ears are huge!

Ears are huge!

 And now its all apart. The helmet body is in three pieces which I will be making into one.

And now its all apart. The helmet body is in three pieces which I will be making into one.

After taking it apart, cleaning the glue, sanding the paint, I am ready to start rebuilding the helmet. I started by tack welding the front and back pieces together through high-friction plastic welding


 Taped the front and back together while I tack weld the pieces together.

Taped the front and back together while I tack weld the pieces together.

 Tack welding the lid to the sides. I will be welding the whole helmet.

Tack welding the lid to the sides. I will be welding the whole helmet.

 Completed weld before sanding and smoothing.

Completed weld before sanding and smoothing.

Next update on helmet to come, It will be posted with this section.