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Hoth Trench Trooper WIP
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
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PostPosted: Sat Oct 05, 2019 9:15 am    Post subject: Reply with quote

I decided to have a go at making the hat (soft helmet) myself. After looking at a number of reference photos including some of a
Hoth Trooper hat on display at Galaxy's Edge taken by a friend of mine.



To me the base looked like a painters cap to me, so I started there.
I purchased 3 inexpensive painters hats online.

I also utilized Angel Monkey's tutorial again
http://costumesandartwork.blogspot.com/2009/05/smaller-hoth-hat-tutorial.html

I started with the front and top brims. I cut the front brim off one of the caps and used it as the top brim of the Hoth hat. I made some bias tape from the left over fabric I made the pants with.
I could have purchased the bias tape, but I wanted the colors to match.
Here's a great tutorial on how to make your own bias tape.
https://youtu.be/9TxwfCWGUkY

My little sewing machine wasn't able to punch through the brim so I used CA glue, since it dries faster than E6000, to attach the bias tape to each brim.

I pinned the top brim to the front of the cap and then hand sewed it together.


Another strip of bias tape I stretched across the edges where the top and front brims meet and secured it with some stitching and glue.


For the back brim I measured the distance around the back of the cap and created a pattern. I cut it using some fabric left over from the jacket.
I also cut some embroidery backing an added it to create some rigidity.

Pinned and sewed it all together.

More bias tape along the top edge of the back brim.


For the neck cover I made a pattern based on Angel Monkey's (see link above) and modified it to my measurements. I used pre-quilted fabric for this portion.

Then sewed some bias tape along the bottom edge

The back brim was sewed to the neck cover.

The back brim and neck cover gets sewn to the sides and back of the cap. (Neglected to get pics of this step Confused )
I then made the tabs for the goggles strap.

These were attached evenly across the neck cover.

Some velcro sewed to the bottom of each tab.


Lastly sewed a chin strap with some velcro to the front of the neck cover.



Overall I think it came out pretty acceptable.

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Arson_Dex (Lawrence)
Active Legion Member


Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Fri Oct 11, 2019 5:17 pm    Post subject: Reply with quote

I had been working on the belt when some greeblies I ordered came in.

I ordered these from Mos Eisley Surplus & Mercantile Etsy shop.
https://www.etsy.com/listing/705211936/esb-hoth-trench-trooper-greeblie-kit?ref=shop_home_active_3&frs=1
Awesome work and quick turn around.

I attached the comm device onto the cap using some industrial velcro.



I ordered some rose pruning gloves from Amazon and glued the wrist comm device onto the left glove with some E-6000.


I'm just about done with the belt and will post that up soon. Also started work on the goggles.
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Sun Oct 13, 2019 2:38 am    Post subject: Reply with quote

Finished the goggles last night. I started with a pair off my old paramedic helmet. I removed the black elastic strap from them and the foam around the vent holes.

I removed the lens and set it up for some white paint.



On the lens I scraped off the logos lightly with a razor.

I cut a yellow lens cover from a yellow document divider and placed it to the inside of the lens.



For the blue vents on top I fashioned the shape from some foam and gave it some blue paint.

Some CA glue to the top of the goggles


The goggles sit a little big on the hat, but I think it works fine.
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Sun Oct 13, 2019 3:17 am    Post subject: Reply with quote

The belt went quickly once I got the materials needed. I ordered a parade buckle online that closely matches some of the reference photos.



For the disc in the center I cut 3 discs from some thin abs and glued them together to make it thicker.

I used some plastic beads with the backs cut off for the little greeblies on the disc. Some CA glue to attach to the disc.

The buckle was too shiny and new looking so I light sanded it to accept some paint and then glued the disc to the buckle.

After a coat of primer

some metallic silver paint

Some black wash and clear coat


For the belt itself I used the 2 inch strapping and cut some fabric strips to cover the strapping.

Stitched one line down the center and two more between the center line and each edge.


Folded one end of the belt through the buckle and sewed.

At the other end sewed some velcro to secure the belt.

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kman ()
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Joined: 25 May 2016
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Location: Tarzana, CA
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PostPosted: Sun Oct 13, 2019 6:11 pm    Post subject: Reply with quote

WOW! Those blue goggle vents came out amazing! How did you do that, exactly?

Belt looks fantastic, too. Is that the British parade buckle that they determined was the actual base for the screen-used belts? Either way, you did a terrific job.
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Mon Oct 14, 2019 1:43 am    Post subject: Reply with quote

kman wrote:
WOW! Those blue goggle vents came out amazing! How did you do that, exactly?

Belt looks fantastic, too. Is that the British parade buckle that they determined was the actual base for the screen-used belts? Either way, you did a terrific job.


Thanks! I cut a piece of thin foam and used a hot iron to melt holes in it. I then folded them over and glued with some E-6000. I sanded down the edges, put a coat of modge podge on them and them some blue paint.


I found the British parade buckle online, but one company didn't ship to the states and the shipping costs from the others in the U.K. were pretty steep. I found a company in San Antonio that sells a near identical one.
Glendale Parade Store. https://www.paradestore.com/index.php/uniforms/belts-buckles/parade-belt-buckles.html
The cost was fair and shipping prompt.
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Mon Oct 14, 2019 2:05 am    Post subject: Reply with quote

I glued the last of the greeblies to the vest. I lined everything up as close to the reference photos has possible and used some E-6000 to glue directly to the vest.



So I currently have all the required items for approval submission including three of the formal requirements.
I have an A-280 rifle I'm awaiting shipment on and I plan on adding a backpack , holster and DH-17. I think i'll submit for approval now, after a couple of touch ups, and then add those items for approval later as I get them.

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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Thu Oct 31, 2019 4:32 pm    Post subject: Reply with quote

I received some really good feedback from the judges after submission. One of the things they wanted to see was a fuller vest. When I made the 1st one I only used one layer of batting. I made a 2nd and this time used 4 layers of batting.
I really like the 2nd vest better.

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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
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PostPosted: Tue Nov 12, 2019 12:14 am    Post subject: Reply with quote

Made a couple modifications to the vest again. Removed some of the padding from the sides and added some stitching to divide the front from the sides.

The vest seems to sit better on my body now
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Tue Nov 12, 2019 1:37 am    Post subject: Reply with quote

Decided to make some belt grenades and a holder.
I looked at the costume references and some movie screen shots to get an idea of what they should look like



I went to home depot and got a few things I could use to replicate them.
1" PVC pipe, 1 1/2" rubber washers, a 3/4" bolt and matching nut (not pictured). In addition I used two caps from toothpaste tubes and some thin ABS plastic from a "for sale" sign. I also used some rollers from rolls of dog waste bags.


I estimated the size of the cylinder portion to be about 4 inches long and cut that length from the PVC pipe.
From the abs sheet I cut a disc the same diameter as the pipe.

I glued the discs to both ends of the pipe and sanded the edges flush.


One of the rubber washers gets slid over the pipe about 1 1/4" from the end and glued.

I cut the rollers to about 3/4" length and then cut them in half lengthwise.

I then glued the half rollers to the pipe above the rubber washer 180 degrees from each other.

The second rubber washer gets slid over the pipe and on top of the half rollers. and glued.

On the bottom end I glued the toothpaste tube caps.
I cut two triangular pieces from the ABS to fit along the caps and down to the edge of the pipe.

I glued the triangle pieces in place (180 degrees from each other) and then sanded down any excess.

For the top I made a mold from the bolt and nut and casted a resin piece from it. I used a simple mold and casting kit from the art store.

I glued the casted piece to the top of the pipe section.


Applied a coat of primer.

Some metallic silver paint.

Finally some black wash and some clear coat.
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Arson_Dex (Lawrence)
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Joined: 30 Jan 2019
Posts: 40
Location: Los Angeles, Ca
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PostPosted: Tue Nov 12, 2019 1:58 am    Post subject: Reply with quote

For the belt holder I took some scrap white fabric and cut a piece that would be about 7" x 5" plus seam allowance. I sewed some interfacing to the fabric.

I then sewed some 1 1/2" elastic loops to the fabric and interfacing.

I folded the outside in and sewed the piece together to make a tube.

I turned it right side out and pressed the it down so it sits flat on the belt.


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PArmstr (Patricia Armstrong-Krauss)
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PostPosted: Tue Nov 12, 2019 8:20 am    Post subject: Reply with quote

Great job.
_________________
GRRRL-Squad-Leader 2019

Costumes: jawa, rebel fleet trooper ANH, signals intelligence technician (Rogue One), Rebel Vanguard (Hasbro action figure), Battlefront female desert rebel trooper, Senior Officer (Rogue One)

WIPs: Yavin Operations Officer, Yavin Operations Trooper, EA Battlefront II Tatooine Specialist

Wishlist: Scarif Marine
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Arson_Dex (Lawrence)
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PostPosted: Sat Nov 16, 2019 7:42 pm    Post subject: Reply with quote

PArmstr wrote:
Great job.

Thank you! Very Happy
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Arson_Dex (Lawrence)
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Posts: 40
Location: Los Angeles, Ca
Medals: None

PostPosted: Fri Dec 13, 2019 3:47 am    Post subject: Reply with quote

So the base costume was approved YAY!
In addition I wanted to added some accessories such as the belt grenades.
I wanted to work on the hard pack next because I believe this piece really brings the costume together.
I used a few photos and screen shots as my references.


Finding the aluminum pack frame proved to be difficult and pricey. I thought I could construct one with aluminum conduit and a bender. Realizing I wasn't skilled enough with a bender to make the angles I needed I scraped that idea. Reading various other tutorials I decided the go with PVC pipe to construct the frame. Some of the PVC shaping tutorials show how to bend the PVC using a heat gun and sand. Wanting to avoid the mess of sand (I hate sand!) I found some PVC with pre-angled sections. Looking at the reference pics I figured the frame consisted of straights, and a couple of 90 degree and 45 degree angles.
Below are the pieces I bought all at Home Depot for the frame.

You'll also notice some "L" brackets and some non-scratch chair feet. The kind you stick under the legs of your dining chairs to avoid scratching up the floor.
The PVC is 1/2"
I cut the coupling ends of the angled pieces off so that when I put the pieces together it will look like one continuous piece of pipe.

Measurements of my back and comparing to the reference pics I estimated the size of the frame should be about 16" wide x 25" long. I cut the straight pieces to lengths that would allow this.

With the coupling ends gone I needed something to secure the pieces together. I used wooden dowels for this. The inside diameter of the pipe was smaller than the dowels so I had to widen it.

Using the dowels and CA glue I pieced each section together

For the cross bars I cut the lengths of straight PVC needed and made rounded indentations at each end to fit with the vertical pipe.

To secure the cross bars I used the "L" brackets. I measured where I wanted them on the frame and screwed the brackets into the PVC pipe.


For the top cross bar I left the ends straight and made rounded indentations to the top of the vertical pipes.

Once everything was pieced together I applied some Bondo to the joints to cover the joint lines, sanded and applied some primer and then metallic silver paint. I also put a matte clear coat over it.

For the ends of the top cross bar I painted and glued the chair feet.

Once I had made the boxes for the pack I realized I needed another cross bar so the bottom box sits right.
I took a small diameter pipe like for gardening irrigation, drilled holes into the frame and glued the small piping into the holes.
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PArmstr (Patricia Armstrong-Krauss)
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Location: Neunkirchen/Saar, Germany
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PostPosted: Fri Dec 13, 2019 11:56 am    Post subject: Reply with quote

Congratulations on the approval of your Trench Trooper. Your hard pack frame is amazing. I wish I had your skills.
_________________
GRRRL-Squad-Leader 2019

Costumes: jawa, rebel fleet trooper ANH, signals intelligence technician (Rogue One), Rebel Vanguard (Hasbro action figure), Battlefront female desert rebel trooper, Senior Officer (Rogue One)

WIPs: Yavin Operations Officer, Yavin Operations Trooper, EA Battlefront II Tatooine Specialist

Wishlist: Scarif Marine
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