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CrookKnight

Crookknight's Battlefront Magmatrooper Build V2

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This is a build thread I originally did back in early 2017.  This should be helpful for people looking to build there own.  the pack ended up a little wider than I wanted, but that can be adjusted.  I will try to update some of this as soon as I can with my latest V4 pack.  Of course, most of that is 3D printed.  What you will see in this build thread is things be made from scratch.

I will be updating some of the photos and adding how to build the shin armor.

I am going to show each and every step on this build, so if you would like to build it for yourself, you should be able to.  This is a very technical build with some materials we do not typically use.

 

On this first post, I will continue to update the materials list as I go.  This will be a slow process, but the end results should be very good.

 

UPDATED ON 1/8/2017

 

MATERIALS:

 

 

TOOLS NEEDED:

  • Small and medium exacto knife.
  • Sharp Scissors
  • Red Pen
  • Belt Sander - Table Version
  • Dremel with circular butting blade for cutting acrylic plexi glass
  • Full face shield for safety

 

CURRENT PROGRESS (PHOTO) OF MY BUILD

 

 

 

 

20170115_143240_zpsfiaoqhzm.jpg

 

20170115_143308_zpsvgsavl8p.jpg

 

20170115_143240_zpsfiaoqhzm.jpg

 

20170115_143156_zpsdiixts3k.jpg

 

20170115_143132_zps3ij0qkic.jpg

 

REFERENCE PHOTO - From Battlefront Game:

 

TK4_zpsriwmdadx.png

Magma%20Face%20Shot_zpsxwy2tv4n.jpg

image_zps0yttoq2l.jpeg

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CONSTRUCTION SECTION 1:

THE FINS:

The fins can be seen on the left and right side of the pack. They appear to be silver in color and spaced equally apart.

The first step is to make the stencils. You will need to make 4 different stencils. See below:
c97aa31e-4ddc-4bc1-b3d4-bff9a2d74b28_zps

Fin Stencil 01:
12cm x 12cm with (2) 2cm Radii.
20161214_155347_zps12vd5r8n.jpg

Fin Stencil 02:
11cm x 10cm with (2) 2cm Radii.
20161214_155357_zps3arsinal.jpg

Fin Stencil 03:
10cm x 8cm with (2) 2cm Radii.
039dc4e2-aae9-44e1-9747-9d5d24b89585_zps

Fin Stencil 04:
9cm x 6cm with (2) 2cm Radii.
bb6e7645-f649-4f08-82d0-c4ecffbce630_zps

From these we will be cutting 14 fins.

I ordered the following material for the fins:
1/8" thick acrylic plexi glass sheets, clear 12"x 24"
Acrylic_Page_1_zpstw60fe8m.jpg
Once this arrives, I will be able to begin cutting. Expected delivery is 12/16/16.

 

12/18/2016:

 

Alright, the material for the fins, arrived.

 

I decided to leave the plastic cover on the plexi to make it easier for me to trace the stencil. 

 

First, I placed stencil #1 on the bottom corner of the plexi.  This is so I could have 2 good straight edges to work with.  I then traced the stencil with the red pen.

 

20161218_164654_zpsmhtuay0e.jpg

20161218_164725_zpsff62acgh.jpg

 

Next, I put on the protective face shield and used the dremel with the circular blade to make the cut where marked by the red pen.  If you go slow enough, you can keep it in a straight line.

You will notice I cut the 2 corners at a 45 degree angle.  I will shape it properly on the sanding table.

20161218_165158_zps92fpodcg.jpg

 

I then sanded the edges to make a smooth radius at the corners.

20161218_165426_zpsysgcrpzx.jpg

 

The end result...I will now cut all of the remaining pieces (14 total) and then apply an aluminum type spray paint.

20161218_165431_zpshuozlrnc.jpg

 

I wanted to go ahead and test the paint adherence to the acrylic, so I painted 4 fins.

 

First, I cleaned off the plexi glass with very fine steel wool to make for a smooth surface the paint would stick to.

20161221_192420_zpsfqchet7m.jpg

20161221_192431_zpsrkn04ccq.jpg

 

Next I used a premium Chrome Aluminum Gloss Spray Paint from a local hardware store.

20161221_192749_zpsel6el50c.jpg

 

I laid the fins out to paint 1 side at a time.

20161221_192804_zps0bdfbyvg.jpg

 

I then applied 2 coats to each side.  This is what I ended up with.  I am happy with this result and will continue with this method for all remaining fins.  Unfortunately, I did not order enough of the material, so I will have to wait for it to come in.

20161221_192857_zps88pqacxf.jpg

 

Finally finished all 20 pieces.  This has got to be the most difficult part of this build.

20161225_151619_zpsqpzhw47e.jpg

 

Made some good progress on the Fins / Valves.....Here are some of the pictures.  I will add details and more photos tomorrow.

 

20170106_195437_zps97jmbmg1.jpg

 

20170106_201403_zpssfkmphog.jpg

 

 

20170106_201407_zpsbvznfybg.jpg

 

 

20170107_074349_zpsyk3ynjfi.jpg

 

 

20170107_080626_zpstn9suq9h.jpg

 

 

20170107_083748_zpsgc88hpo4.jpg

 

 

20170107_083950_zps2uhdnmwk.jpg

 

 

20170107_083953_zpsclerlmoo.jpg

 

 

20170107_084321_zpsc5ynwuyo.jpg

 

 

20170107_084335_zpsahuen8lo.jpg

 

 

20170107_103415_zpskd4cclqw.jpg

 

 

20170107_103447_zps1hhn4rjl.jpg

 

 

20170107_104813_zpsb2pwrozm.jpg

 

 

20170107_153843_zpskrimhrlm.jpg

 

 

a79154be-ce42-451b-a798-3346633a8ca9_zps

 

 

20170107_184410_zpsjkv5nfze.jpg

 

 

20170107_154503_zpsqgapiixt.jpg

 

 

20170107_154605_zpsggduneds.jpg

 

 

20170107_154725_zpspgziazem.jpg

 

 

20170107_184410_zpsjkv5nfze.jpg

 

 

20170107_184742_zpsd3uub6hd.jpg

 

 

20170107_204932_zpsxwqenba2.jpg

 

 

20170108_152238_zps5gpmj1t8.jpg

 

 

20170108_201742_zpsowd3mz3t.jpg

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Added the following to the FINS SECTION above.

 

I wanted to go ahead and test the paint adherence to the acrylic, so I painted 4 fins.

 

First, I cleaned off the plexi glass with very fine steel wool to make for a smooth surface the paint would stick to.

20161221_192420_zpsfqchet7m.jpg

20161221_192431_zpsrkn04ccq.jpg

 

Next I used a premium Chrome Aluminum Gloss Spray Paint from a local hardware store.

20161221_192749_zpsel6el50c.jpg

 

I laid the fins out to paint 1 side at a time.

20161221_192804_zps0bdfbyvg.jpg

 

I then applied 2 coats to each side.  This is what I ended up with.  I am happy with this result and will continue with this method for all remaining fins.  Unfortunately, I did not order enough of the material, so I will have to wait for it to come in.

20161221_192857_zps88pqacxf.jpg

 

Once I get the remaining material in, I will finish this section.

I wanted to go ahead and test the paint adherence to the acrylic, so I painted 4 fins.

 

First, I cleaned off the plexi glass with very fine steel wool to make for a smooth surface the paint would stick to.

20161221_192420_zpsfqchet7m.jpg

20161221_192431_zpsrkn04ccq.jpg

 

Next I used a premium Chrome Aluminum Gloss Spray Paint from a local hardware store.

20161221_192749_zpsel6el50c.jpg

 

I laid the fins out to paint 1 side at a time.

20161221_192804_zps0bdfbyvg.jpg

 

I then applied 2 coats to each side.  This is what I ended up with.  I am happy with this result and will continue with this method for all remaining fins.  Unfortunately, I did not order enough of the material, so I will have to wait for it to come in.

20161221_192857_zps88pqacxf.jpg

 

Once I get the remaining material in, I will finish this section.

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CONSTRUCTION SECTION 2:

 

LEFT SIDE FRONT PLATE AND PANELS

 

First, I decided to create the left and right bottom of panels.  As I continue to do this, I will make it more clear the area I am working on.  I am learning this as I go along.

 

I made templates out of cardboard, so I could do this again and again.

 

This is left side panel:

20161221_202736_zpsm1janvwu.jpg

 

This is the right side panel (plate):  Before I trimmed it.

20161221_201140_zpseb3i1lx2.jpg

 

I then placed the template on the 1/4" PVC Expanded Plastic Sheet and traced both of them.

 

At this point, I used the dremel tool to make the cut and the table sander to clean the edges.  Below is the final result.

20161221_210316_zpswfv9vnil.jpg

 

Below is the template I made for the front plate that these 2 side plates attach to.  Once you cut this out of the PVC, it has to be bent into shape by heating up the pvc where you need to bend it.  Unfortunately, I did not take any pictures of this process.

20170102_173754_zpsnwhg1hcr.jpg

 

Below was my first attempt at glueing all of the pieces together.  However, I glued the side pieces on backwards.  Do do not do it this way.

20170101_100613_zpshsquymz6.jpg

After I painted it, I realized I had put the longer side with the notch on the wrong side.  When facting the pack, it needs to be on the left.  See pictures below:

20170102_122353_zpszhirpqpx.jpg

Next, I cut the backplate at 500 mm x 250 mm, as a starting point.  this will be trimmed as I go along.

 

I then placed the piece on the back piece and traced out the right section.  The piece to the left will need to be removed.

20170102_153504_zpslp4c1a8j.jpg20170102_153612_zpsmyl519mm.jpg20170102_153744_zpsq4ro7tqw.jpg

 

I then glued the 2 pieces togther..

20170102_154239_zpsy1jjgoth.jpg

Now that we have got the bottom panel / plates glued together, it is time to work on the upper portion.

 

I started with a template created from cardboard.

20161221_195919_zpst2r8tsgu.jpg

20161221_200020_zpspk6yepxd.jpg

 

I then traced the template, confirmed the measurements, and cut out the piece from the PVC Foamboard.

20170101_192331_zpsigifzkef.jpg

 

I again used the heat gun to bend the plate (panel) where I needed to.

20170101_194508_zps62z6ngr3.jpg

20170101_194514_zpsqhsltb0c.jpg

 

At this point, I measured and traced out the 2 side pieces that go with this face plate.  Use this template for both plates.  Only need the notch in 1 plate.

 

20170101_191654_zps1nxgjmf0.jpg

20170101_192029_zpsjhwkfrha.jpg

 

I am waiting to cut the notch until I can confirm placement.

20170101_191841_zpsn0uq6tyj.jpg

 

Next cut out 2 identical pieces that will go on the face plate.  At some point, I will label the pack and reference the pieces so this is easire to follow.  Measurements will also be clarified and added to all drawings and text.  Since this is a work in progress, I am having to do things, via trial and error.

20170101_203952_zpstcjjiyrg.jpg

 

These 2 pieces will be bent 90 degrees to allow for the proper sizing.  Next time, I will not bend these and just create 3 separate pieces, in lieu of 2.

 

Bending is made possible by applying heat to the PVC Foam board via heat gun.

 

20170101_204808_zpsanr3whsl.jpg

 

I then slid these onto the face plate and allowed for 15 mm around the edges..  Glued, taped, etc....

20170101_205441_zpswrc7bi3c.jpg

20170101_220426_zpshad5mg6d.jpg

20170101_220430_zpsv3ayqmwu.jpg

 

Once the glue dried.  I sanded it down and prepared it for painting.  For now, I applied 2 coats of gray primer paint (flat).

20170102_122030_zpsukqhfwsc.jpg

20170102_122033_zpsy8h1gbke.jpg

20170102_122227_zpsaz2cotcb.jpg

 

Ok.  I have spent the last couple of days working ******* this thing.

 

First thing I noticed was that I put the side panels on backwards.  The part with the notch needs to be on the left side of the pack.  Below is the corrected version.

 

20170102_122353_zpszhirpqpx.jpg

 

After I corrected that mistake (this happens when working on a prototype for future builds). I cut out the back plate 500 mm x 250 mm.

 

d3a1d7c0-1fde-4bff-80a6-60ddfee61f68_zps

 

I then cut out the 215 mm x 58 mm section at the bottom right.

 

20170102_153744_zpsq4ro7tqw.jpg

 

Then glued the finished portions to the back plate.

 

20170102_154239_zpsy1jjgoth.jpg

 

I then glued the previously cut top angles to the back plate. (only 1 shown below)

 

20170107_093444_zpsoqi3yqek.jpg

 

When I test fit the top plate over these,  it appeared they were too long.  Therefore I had to remove them and cut them down.

 

20170107_163907_zps9ke8jph4.jpg

 

At the same time, I shortened the back plate by 75 mm and glued the two angle pieces back on.  You will notice the fins and some other pieces are on the left side of the photo.  These will be discussed in another section.

 

20170107_164845_zpswwxcgtzs.jpg

 

For what I am calling the access hatch on the face plate, I created this out of the 1/8" PVC board and cut out a 14 cm x 13 cm rectangle.  I had actually cut out a hole on the face plate at 13cm x 12cm, however, I could not get it to function correctly.  So for this prototype I am going to keep the access hatch on top of the plate instead of flush.  I will see if I can make an operational hatch for Version 3.

 

20170107_173258_zpsxpn0k7pk.jpg

 

For the upper small "Name Plate" on the face plate, I cut a 4 cm x 6 cm rectangle out of the same 1/8 pvc board.

 

20170107_174649_zpsudnfjjzl.jpg

 

These are the 2 plates after 2 coats of the flat gray spray paint.

 

20170107_184736_zpsrvgmnob4.jpg

 

Here is a picture with the plates attached.

 

709d8a9a-2e56-4bf3-b909-6f953ea3129d_zps

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Ok.  I have spent the last couple of days working ******* this thing.

 

First thing I noticed was that I put the side panels on backwards.  The part with the notch needs to be on the left side of the pack.  Below is the corrected version.

 

20170102_122353_zpszhirpqpx.jpg

 

After I corrected that mistake (this happens when working on a prototype for future builds). I cut out the back plate 500 mm x 250 mm.

 

d3a1d7c0-1fde-4bff-80a6-60ddfee61f68_zps

 

I then cut out the 215 mm x 58 mm section at the bottom right.

 

20170102_153744_zpsq4ro7tqw.jpg

 

Then glued the finished portions to the back plate.

 

20170102_154239_zpsy1jjgoth.jpg

 

I then glued the previously cut top angles to the back plate. (only 1 shown below)

 

20170107_093444_zpsoqi3yqek.jpg

 

When I test fit the top plate over these,  it appeared they were too long.  Therefore I had to remove them and cut them down.

 

20170107_163907_zps9ke8jph4.jpg

 

At the same time, I shortened the back plate by 75 mm and glued the two angle pieces back on.  You will notice the fins and some other pieces are on the left side of the photo.  These will be discussed in another section.

 

20170107_164845_zpswwxcgtzs.jpg

 

For what I am calling the access hatch on the face plate, I created this out of the 1/8" PVC board and cut out a 14 cm x 13 cm rectangle.  I had actually cut out a hole on the face plate at 13cm x 12cm, however, I could not get it to function correctly.  So for this prototype I am going to keep the access hatch on top of the plate instead of flush.  I will see if I can make an operational hatch for Version 3.

 

20170107_173258_zpsxpn0k7pk.jpg

 

For the upper small "Name Plate" on the face plate, I cut a 4 cm x 6 cm rectangle out of the same 1/8 pvc board.

 

20170107_174649_zpsudnfjjzl.jpg

 

These are the 2 plates after 2 coats of the flat gray spray paint.

 

20170107_184736_zpsrvgmnob4.jpg

 

Here is a picture with the plates attached.

 

709d8a9a-2e56-4bf3-b909-6f953ea3129d_zps

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CONSTRUCTION SECTION 3:

 

In order to keep each post to a reasonable length, I will be breaking the remaining portions of the builds into additional sections.

 

Below is my latest progress.  I know I am currently jumping around a little bit, however, I only have time at night to work on the build, so I have to work on different items at the same time.  Once I am 100% complete, I will go back and make final revisions.

 

I am currently working on the copper piping on both the left side and right side of the pack.

 

For this I am using 2 cm diameter copper pipe and elbows. I cut the pipe to 5.5 cm in length.  I cut 6 pieces and used 4 elbows for the left side.

 

This is for the top section:

20170110_185731_zpsmrn3udjg.jpg

 

Bottom section:

20170110_191251_zpsik38g9mj.jpg

 

Glued the 4 pieces onto the Fins and Pack.

20170110_203420_zps1sqvutnl.jpg

 

For the 2 exhaust ports (bottom right of the pack), I started with 2 plastic drink bottles:

20170107_165052_zpspystnvwv.jpg

 

I then removed the labeling and cleaned them:

20170107_171346_zpssde2gcp7.jpg

 

I then cut off the bottoms of the bottles and painted them flat black.

 

While I was waiting for them to dry, I worked on the angled portion of the exhaust ports.  I decided to use a cardboard tube container.  It is very thick and durable.  I cut the pieces at a 45 degree angle.  In order for them to fit properly over the bottle, I had to cut a slit in the back..

20170107_190308_zpswbvaueed.jpg

 

20170107_190315_zps2rk0bkrk.jpg

I then added many coats of white primer and gloss paint to these pieces.  Once dry, I glued them to the bottles.  You will notice that one of the bottles, I cut shorter to match the reference pictures.

20170108_152249_zpszcmbjwgu.jpg

 

Next I worked on the box that is on the bottom right of the pack, directly adjacent to the exhaust ports.

 

Below are the photos.  I will add the text, later.

20170108_184011_zpsfgnvdpre.jpg

 

20170108_184645_zpswexvgonb.jpg

 

20170108_191638_zpsd4bjpbnf.jpg

 

20170108_191719_zpsl98qxyns.jpg

 

20170110_203349_zpspsmghyrv.jpg

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Getting very close.  I have added the tubing, reinforced the back, added the shoulder straps, completed the copper work, attached the exhaust port, and many other items.

 

I still have to correct the imperfections, weather the pack, add the vertical details on the fins, connect the tubing to the helmet and add the respirator.

 

Below are some more pictures of the progress:

 

20170114_155001_zpsotkbjoko.jpg

 

20170115_135907_zps4dmvwgxp.jpg

 

20170115_140652_zpsdhn54fjm.jpg

 

20170115_141004_zpsf8jfhs6a.jpg

 

20170115_143132_zps3ij0qkic.jpg

 

20170115_143156_zpsdiixts3k.jpg

 

20170115_143237_zps91s3t6nb.jpg

 

20170115_143240_zpsfiaoqhzm.jpg

 

20170115_143308_zpsvgsavl8p.jpg

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THIS WAS THE OLD WAY I DID IT.  NOW I 3D PRINT THIS PART.  IT IS MUCH LIGHTER AND MORE ACCURATE.

 

The respirator model and mold are complete.  This is a picture of the first resin one.  Now all I have to do is add the red LED Light, paint black and install the magnets to hold onto the helmet.

 

I am now at the point where I can put the final touches on this entire package (pack, shin armor, respirator system).

 

20170127_064255_zpsldshsqi1.jpg

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Finished with this build.  Will post more pics and details of the build, later.  But below are the photos.

 

 

 

 

20170205_162246_zpsqftjlxlm.jpg

 

 

 

 

 

20170205_162236_zpsyjtp7f6l.jpg

 

 

 

 

 

20170205_162226_zpsq7hdn29v.jpg

 

 

 

 

 

20170205_162221_zpsbcwgnjix.jpg

 

 

 

 

 

20170205_162213_zps63niqg1y.jpg

 

 

 

 

 

20170205_162205_zpsfpkbr8fg.jpg

 

 

 

 

 

20170205_162154_zpsv3izicmm.jpg

 

 

 

 

 

20170205_162146_zpslvrmsdes.jpg

 

 

 

 

 

20170205_162139_zpslca0wxpm.jpg

 

 

 

 

 

20170205_162131_zpsrpxktvqk.jpg

 

 

 

 

 

20170205_162122_zps8qlmvfup.jpg

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On 2/13/2017 at 1:00 AM, Daetrin said:

IIRC the shins are supposed to be grey? IIRC you were re-painting them - were they completed?

Shin armor has been repainted.   Pictures are below.:

 

20170213_063933_zps8rtu38gp.jpg

 

1e2edc4f-df55-46a5-af8a-fc8f52268e38_zps

 

I will also update this in Spec Ops.

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Wow! Great job, Shawn! Thanks for sharing your process!

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Nice job Shawn!  Looks terrific!

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Amazing work as always Shawn!

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Wow! Great job, Shawn! Thanks for sharing your process!

No problem

Sent from my SM-G930P using Tapatalk

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Amazing work as always Shawn!

Thank you

Sent from my SM-G930P using Tapatalk

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Amazing work as always Shawn!

Thank you

Sent from my SM-G930P using Tapatalk

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