Edit June 2013

For extra help go to YouTube Daves Garage

WHITE BODY ARMOUR ASSEMBLY INSTRUCTIONS

Important Information! Read Me First

CONTENTS Do This First Go shopping Start here first / Rear Canister Helmet Assembly Body Assembly Leg assembly Page 4 Page 5 Page 6 Page 8 Page 15 Page 20

Do This First!
Open the box and check that all the plastic parts are included and no parts are missing! Look at the pictures below and compare the parts you have received with the pictures. If you have any parts missing, (we make mistakes sometimes) please email [email protected]

New designed Front and back armour. Makes the armour adjustable. It is easier to wear and use the toilet!

Go Shopping!
Go to your shed, garage or the local shop and make sure you have all the items in the picture below

T Cut or Plastic polish is great for removing the scratches you will get on your kit. The scratches will come out with a little rubbing. There may even be small scratches in the plastic when you take it out of the box. They will come out very easy. Hot Glue gun and glue is the most important thing you will need. It will hold everything together. Dont think bad that your suit is glued together. All modern cars are glued together and how much more do they cost! Pop Rivet gun and rivets. You will need these to hold the helmet in places that need to be stronger than glue. Hand drill and drill bits to match the size of the rivets you will be using. Screws a few small screws will be needed to screw the ear pieces to the helmet as they are better than rivets. Spray Paint in 2 colours. Black and silver for the rear canister and the chin bit Velcro will be needed to add to the elastic straps so you can fit the armour to your body. You can buy the cheaper type that you can use hot glue to fix to the armour or you can buy the expensive stuff that is self sticking. Sandpaper to rough the plastic so the paint and the glue will stick to it.

Start Here First

Rear Canister
Take the parts in the below picture and then rub the blue part a little with some sandpaper. You can then spray them with the silver paint. Try and spray outside, weather permitting! And give a few coats to make sure the colour is deep.
When you are waiting for the silver to dry you can start spraying the chin piece MATT black. Rub it gently with sand paper again before you spray it When the paint is dry then you can fit 1 of the end caps on the end. Look at the picture. From the top pour lots of glue from the glue gun into the lowest point possible so it sticks with the end cap.

When the glue is fixed then put the other end cap on a flat surface and fill it inside at the lowest points full of glue. Then add the part completed canister to the end cap and let the glue cool with the cap flat on the table! This will be fitted to the belt at the end of the assembly with a bolt or a rivet. You will see later! 7

When you open the blue tube then you will see all the smaller parts are stored inside

Same for the adult and the child kit.

The Helmet This is the hardest of all of it. You can do this next or you can do it last! Follow the pictures as they will explain most.

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These Pictures are the child helmet

Now you must make the helmet strong by adding hot glue to all of the joins inside the helmet

For 501st legion approval you must cut the airholes in the face.

Now start on the ear pieces.

Make sure that the ear piece fits the shape of the helmet. If it is not perfect then use the sand paper to make it fit

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The adult helmet has a small gap. These pictures are of the prototype Childs helmet. Now glue the eyes with the hot glue into place. Also take the black chin piece. Offer it up to the helmet so you can see where it fits. Now add the black sticker that fits in that place. Now fill the chin bit full of hot glue and allow cooling a little. You can now fit it to the helmet ensuring the glue does not pour out. The 2 strips of rubber can now be trimmed to fit the brow of the helmet and under the helmet. Fix it again with hot glue.

To finish the Areators

First spray it with silver paint or if you are really clever you can make a kind of grid in the plastic with the sandpaper and then dry brush the silver paint on to make the silver grid effect! It actually looks quite good You can spray with silver paint then when it is dry you can then use a fine black pen and put a grid on them

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Body Assembly
Please look at the pictures below. First assemble the belt. Take the belt and the 2 plastic flat strips. Hold them together and the drill through at the ends and then rivet the parts together. Then take some 1 foot Velcro strips and then following the instructions in the picture glue them to finish the belt.

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Now Fit the Velcro and Elastic

Take out of the bag all of the elastic strips. You will see the 2 long strips are for the ab plate and the lower back to be attached to your body like bracers. They will be attached to the Velcro attached at point H, J, K and I on the picture. Point D and L are there to hold the ab plate and the lower back together when it is worn. See the picture below. Point A, B, C, E, F and G are there to hold the drop boxes in place, to hold up the thigh sections and also can be used to ad extra supporting straps around your waste to help to hold the armour steady. You can glue the top and bottom part of the Ab to the front of the belt to hold it in position. The best way is not to glue them. Then you can use the toilet easy!
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Now you have the lower body assembled and can wear it, now it is time to finish the ab plate with the buttons.

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You can see how the upper body armour very easily fits together. Just glue and Velcro.

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The drop boxes and the hand armour are very simple to do. The drop boxes can be strapped to your belt or the ab plate as there is plenty of room to be stuck with Velcro.

The Forearm armour is very basic and is attached with Velcro to your arms.
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The Bicep armour is basically the same as the forearm armour. You can add a little extra piece of Velcro to hold it on your bicep. Either by Velcro to your under suit or Velcro to the shoulder bell.

The shoulder bells (2) are attached to your arm with a elastic strap and also at the top is attached with Velcro to your under suit.

Leg Assembly First make sure you know the parts and familiarise yourself with them!!!

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Start with the thigh/upper leg parts. Follow the pictures below and you will see how they are fitted together with the use of hot glue at 1 side and Velcro at the other side. You can then fit the calf/lower leg parts together. These parts are very easy. ***Please remember that the 2 calf sets are the same. There is no left or right leg there is only the calf armour. It will fit both legs*** First use hot glue to fix the front parts together. Then stick a line of Velcro along the back to hold the 2 halves together.

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Now you should have 2 complete upper leg armour parts that will fit your left and right legs and 2 complete calf armour parts that will fit either leg.

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Now to fit the knee parts! Please follow the pictures below.

The knee belt fitted to the RIGHT thigh and not the left! The triangular piece is fitted to the LEFT calf armour and not the thigh armour
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