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 Hermit's Late Crusader WIP

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Hermit's Late Crusader WIP
« on: Jan 09, 2018, 07:42 PM »
Hey all! I've been lurking for a while now and recently joined in preparation for the construction of my armor!

Anyways, I've just begun getting the materials I have atm into one place and could use as much advice as possible.


^Obviously the jumpsuit will be going under the armor once that's made. I've also heard that the Jango 2piece helmet is allowed for Crusader builds, provided it's been heavily modified (confirmation incase I don't know what I'm talking about?). I'll be removing the earpieces when I get around to the helmet and giving it more of the Crusader look so it doesn't look modern. Likewise, I'm looking around for visors to get rid of the see-through one.

Now, for armor, I have a few options readily available right now--one idea is that I shape the armor with carpet padding and then reinforce it with epoxy resin to make it actually look like armor. Alternatively I use aluminum foil or some other material that's easy to shape and then cover that in epoxy so it's not... well, just aluminum foil anymore. Third is paper mache and/or chicken wire that'll likewise be reinforced with resin. Are any of these options viable or should I scrap those ideas before I do something dumb? :P



Looking forward to feedback/ideas!

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Naran Baatar


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Re: Hermit's Late Crusader WIP
« Reply #1 on: Jan 10, 2018, 12:16 AM »
So yes, you can in theory use a Jango Two-Peice as a base for a Crusader helmet. But it will require a good bit of modification to do so. You will need to not only remove the ear caps, but I would also suggest smooth out the brow ridge, and modifying the shape of the visor form a T to a Y shape. Really by the time your are done with the mods really only the dome itself will be left in the original state. Nothing wrong with that it just takes a good bit of work as does any scratch helmet build does.

With that being said the generally accepted wisdom is to buy your first helmet granted there are only one Crusader Era buckets that are in general production at the NME Props Deathstalker, and then there are a number of people that have 3D Printed Crusader Era helmets that you can custom order those people can be contacted via the Supply Depot which can be found here: http://mandalorianmercs.org/forum/index.php?board=270.0

Now with that being said you can totally scratch build your first bucket, but more often than not doing so generally ends up costing more than just ordering a ready made bucket.

So I am going to just be blunt and say that those materials aren't going to fly for a number of reasons. I would HIGHLY suggest using Sintra (PVC Foamboard) you can get it in 3mm or 6mm thick sheets and general speak you can get a single 4 foot by 8 foot sheet on Amazon for around 15 dollars. Then you simply need to shape it with a heat gun and you have yourself armor plates.

Another good option is to use metal, but that requires that you either already have metalworking tools or easy access to them otherwise that really isn't an choice.

Lastly if your heart is set on a Crusader build something that is key is that you collect reference images, this are crucial for both the build and the approval process for Crusader era kits. You need to be able to point to something from the Star Wars Legends/Canon Material for the Crusader era and say "My armor is based on this"

Re: Hermit's Late Crusader WIP
« Reply #2 on: Jan 10, 2018, 05:55 AM »
So yes, you can in theory use a Jango Two-Peice as a base for a Crusader helmet. But it will require a good bit of modification to do so. You will need to not only remove the ear caps, but I would also suggest smooth out the brow ridge, and modifying the shape of the visor form a T to a Y shape. Really by the time your are done with the mods really only the dome itself will be left in the original state. Nothing wrong with that it just takes a good bit of work as does any scratch helmet build does.

With that being said the generally accepted wisdom is to buy your first helmet granted there are only one Crusader Era buckets that are in general production at the NME Props Deathstalker, and then there are a number of people that have 3D Printed Crusader Era helmets that you can custom order those people can be contacted via the Supply Depot which can be found here: http://mandalorianmercs.org/forum/index.php?board=270.0

Now with that being said you can totally scratch build your first bucket, but more often than not doing so generally ends up costing more than just ordering a ready made bucket.

So I am going to just be blunt and say that those materials aren't going to fly for a number of reasons. I would HIGHLY suggest using Sintra (PVC Foamboard) you can get it in 3mm or 6mm thick sheets and general speak you can get a single 4 foot by 8 foot sheet on Amazon for around 15 dollars. Then you simply need to shape it with a heat gun and you have yourself armor plates.

Another good option is to use metal, but that requires that you either already have metalworking tools or easy access to them otherwise that really isn't an choice.

Lastly if your heart is set on a Crusader build something that is key is that you collect reference images, this are crucial for both the build and the approval process for Crusader era kits. You need to be able to point to something from the Star Wars Legends/Canon Material for the Crusader era and say "My armor is based on this"

Understood, I'll look into the sintra. I do have a bit of copper sheet metal that's pretty strong--if I go the metal route, would that work?

And yeah, I'm being careful about appearance--I'm taking ideas from Rholan Dyre, Mandalore the Ultimate, and this nice set of Crusader armor in the reference pics.


Will provide update soon--might take a week or two to get my hands on some sintra if I go that route!

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Re: Hermit's Late Crusader WIP
« Reply #3 on: Jan 10, 2018, 06:18 AM »
Sintra is a better bet to get what you need. I'm not sure that any of those items can actually be used to creat armor with exception to the epoxy.

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Naran Baatar


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Re: Hermit's Late Crusader WIP
« Reply #4 on: Jan 10, 2018, 08:03 AM »
You could use copper, the only issue there is cost. But if you have enough on hand and the tools to work it correctly. You can use that. But generally speaking to make a kit you need a fair bit of material for example I am 6'3 and for me to make a full set of plates it takes two 4x8 sheets of sintra. Now that is making chest, ab, shoulder, gaunts,back, cod, thigh, shin, hand and boot armor. But it goes pretty quick so just something to keep in mind if you do decide to use your copper.

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Re: Hermit's Late Crusader WIP
« Reply #5 on: Jan 10, 2018, 09:25 AM »
I'm 6'1, 240.  I did a full set of legacy with a little over half of a 4 x 8 sheet -- chest/abs, shoulders, gauntlets, back, cod, shin, knee, hand, and boot armor, even some trauma plating. No thighs, but could easily have gotten that out of the one sheet.  It's really important to plan all your parts and nest everything together to save waste. 

Re: Hermit's Late Crusader WIP
« Reply #6 on: Jan 10, 2018, 09:26 AM »
I think I've got enough copper and the means to shape it. I want to experiment with different things though, so I've been looking more into sintra as well. Is there a recommended wattage for 3mm thick? I found a cheap heat gun that's about 1500 watts and want to make sure it's going to be good enough.

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Re: Hermit's Late Crusader WIP
« Reply #7 on: Jan 10, 2018, 09:34 AM »
If it's more powerful than a hair dryer and less powerful than a propane torch, you should be good.  I have a el-cheapo Harbor Freight heat gun, and I can use either the low or the high setting with good effect.  It's not very picky stuff.  Just don't leave the gun in one spot for too long.  It also doesn't get brittle after multiple heats like ABS can. You can pretty much adjust it as many times as you need.

Re: Hermit's Late Crusader WIP
« Reply #8 on: Jan 10, 2018, 09:36 AM »
I think I've got enough copper and the means to shape it. I want to experiment with different things though, so I've been looking more into sintra as well. Is there a recommended wattage for 3mm thick? I found a cheap heat gun that's about 1500 watts and want to make sure it's going to be good enough.
luckily my heat gun is right next to me. i have a 1200 watt heat gun that is more than enough.

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Re: Hermit's Late Crusader WIP
« Reply #9 on: Jan 13, 2018, 10:20 PM »
I've gotten my hands on some sintra and a heat gun! Unfortunately I'll have to postpone the project as I'm about to return to college, so it'll probably be a few weeks before I have an update. Stay hyped everyone, hopefully I'll be able to join the ranks soon! And thanks for all the help

« Last Edit: Mar 13, 2018, 11:02 PM by Hermit » Logged
Re: Hermit's Late Crusader WIP
« Reply #10 on: Mar 13, 2018, 11:06 PM »
UPDATE 3/13/18: I'm on Spring Break and managed to play around with the heat gun and sintra. Made a torso mannequin and then created the basic shape for a chestpiece out of paper before making the actual piece out of sintra. It'll come in two parts, and once I get to the back I'm thinking of rivets, velcro or strapping to attach it all.



I know it looks a little jagged--I'll be smoothing everything out once I've gotten all the pieces made.

As always, advice, criticism, and words of encouragement are appreciated! I'll try to make some more progress tomorrow, maybe do something with the back unless you all have suggestions on the chestpiece.

« Last Edit: Mar 13, 2018, 11:14 PM by Hermit » Logged
Re: Hermit's Late Crusader WIP
« Reply #11 on: May 20, 2018, 10:47 PM »
UPDATE 5/20/18: (hopefully this doesn't qualify as double/triple posting) Managed to make more progress with the armor. Cod piece, shoulders, and helmet are still WIP, as is attaching the wrist and shin pieces. Lemme know what you think


Back and upper half of the front, nothing particularly special. I used leather straps and rivets to put the pieces together. Also took a bit off the top of the breastplate--it was a little too big and would've made things look awkward.


More riveting and leather straps, plus paint. I'm mixing black, brown, and gold and will probably put another layer on. Shoulders are next--I'll probably attach them via the same leather straps connecting the breastplate to the back.


Clearer image. Same as above, but with more paint. The two pieces off to the side will serve as wrist armor (may have to straighten them out a bit more, but they fit fine) and the ones in the back are part of the leg armor.

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