Daryl's Denuo Novo TLJ FOTK build

[daryldoak]

FISD build log (will contain basically identical posts to this forum):

https://www.whitearmor.net/forum/topic/52587-daryl’s-denuo-novo-fotk-build/


Here's my parts list (will update as parts are added):

armor: Anovos (ordered 1/9/2018)
helmet: Anovos standard (ordered 1/9/2018)
boots: Imperial boots http://www.imperialboots.com/product/trooper7-boots-gloves/
gloves: Imperial boots http://www.imperialboots.com/product/trooper7-boots-gloves/
metal holster: R2Dan on FISD https://www.whitearmor.net/forum/topic/46336-tfa-accurate-first-order-stormtrooper-metal-holsters-run-11/
shoulder brackets: Ukwrath on FISD https://www.whitearmor.net/forum/topic/44120-fs-ukswraths-fotk-shoulder-bell-and-yoke-brackets/
fabric mesh/gaffers tape: Ukwrath on FISD https://www.whitearmor.net/forum/topic/34176-fs-ukswraths-fo-chest-pill-box-fabric-mesh/

Supplies:

Lexan scissors
Painters tape
Clamps
Magnets
E6000
80 grit sandpaper
220 grit sandpaper
400 grit sandpaper
1000 grit sandpaper
2000 grit sandpaper
Behr Paint+Primer Gloss White
Behr Paint+Primer Satin Black
Acetone
Headlight polish
Novus scratch remover 2 & 3

[daryldoak]

Gloves and boots arrived:

Untitled by daryl doak, on Flickr

[daryldoak]

No armor yet, but I added a couple items over the last year.

Ukwrath's FOTK Shoulder brackets, fabric mesh, gaffer's tape:



R2Dan's accurate First Order metal holster:

[daryldoak]

UPS tracking number received today.  Estimated delivery on Saturday 9/13.

Denuo Novo is following through with their commitment.

[daryldoak]

Believe it or not, it finally arrived.

[Nathanzx10r]

4.5 years... Wow! Glad you finally got something.

[daryldoak]

It’s been 4 years since I’ve cut any plastic, and I’m terrified of cutting a kit I’m not very familiar with.  I thought about just leaving it in the box for awhile until someone else creates a build post for me to follow, but then the Denuo Novo instructions were released today, so I figured why not just jump in.

https://lookaside.fbsbx.com/file/TLJ-FO-Armor-Kit-Instructions-08-16-22-sm.pdf?token=AWyQJPss59IRLjNjyPH3Yw3VKU2IwsrsemAHKjIxj8k94zvDhR3dBdkiKlF9p8-gHMFV6Tom-lQvIVWwr5ZTMDlKdlFLb6UKUroEslFS56J7ifhduUv_E3whsDbOf2hamWxcZw5qkSk6mH1jP9HlmEs6FZKR9bhoS151TeaJ0dtDqCwwnXbvy2u2tZcc4531lxAnM1ZNaz3xeEsCD1fZdCF4ifkjUXzlRFuTijxAMlS4CxkEgXoHDdjELqSzSmujNuU

I’m also going to cross-post everything on FISD to make sure I’m on track:

https://www.whitearmor.net/forum/topic/52587-daryl’s-denuo-novo-fotk-build/

So here goes, its arm day!  Rough cutout.

Biceps inner before:


Bicep inner after:


Bicep outer before:


Bicep outer after:


Forearm outer before:


Forearm outer after:


Forearm inner before:


Forearm inner after:


I plan to rough cut all pieces to outside the guide lines, then sand to the proper size.

[daryldoak]

Just received this from Denuo Novo:

Hi Daryl,

The helmet will be The Last Jedi.

Thanks and MTFBWY!
Denuo Novo Customer Service

So this is now a TLJ build.  Changed the title of the thread.

[daryldoak]

More trimming.  My cutting confidence is back, so I was on a roll.

Hand plates before:


Hand plates after:


Test assembled arms:



Onto the legs.

Calves before (partially cut before picture)



Calves after:


Shins before:


Shins after:


Thigh backs before:


Thigh backs after:


Thigh fronts before:


Thigh fronts after:


Knee plates before:


Knee plates after:


Spats before:


Spats after:


Test assembled legs:

[CadBane3]

Looking good! Careful of getting cutting scissor blisters! Lol

[daryldoak]

Looking good! Careful of getting cutting scissor blisters! Lol

Too late, my hand is killing me! 

Thanks!

[daryldoak]

More cutting…

Spine plate before:


Spine plate after:


Cod and butt before:


Cod and butt after:


Torso front/back before:


Torso front/back after.  I split the back in order to make the sides seamless.  And I haven’t cut out the middle tabs in case I need to widen or shrink the torso:


Torso pre assembled:


Inner chest before:


Inner chest after:


Chest before:


Chest after:


Back before:


Back after:


Shoulders and pouch cover before:


Shoulder were really thick so it was a soft pull with really no guide lines on the lower edges (both at the center of the picture), I ended up using the one with the barely visible guideline as a pattern for the lower edge where there was no visible line.  But I cut these pretty far off of the guide lines to be safe.


Shoulders and pouch cover after:


And rough cut is done.  My hand hurts.

[daryldoak]

[daryldoak]

So next I got started on some fine-trimming/sanding, and the place I decided to start was with the biceps. 

I started here because they are pieces that I became worried about while trimming.  Both ends of the larger, wrap-around bicep piece are extremely thin, and one of those ends becomes an important front-facing seam. 

There was a lot of mold curve-back on the ends, so you are required to trim that off so the pieces fit together properly (sorry, no picture). Trimming off the curve-back limits the options you have for how this seam fits together, and also makes the clip slot smaller, which is a problem since you have to leave enough space for the clip to fit in the slot.  Be careful here!

Also, when you trim off the curve-back the pieces loses length (top to bottom), which leave the smaller bicep piece a bit shorter than the bigger bicep piece, so I had to trim the larger piece a bit to make the lengths the same (no picture).  Then I trimmed the rest of the bicep pieces closer to the guide lines (where they existed), and used my best judgement where there weren’t guide lines.

Then I peeled off the protective plastic and rough sanded with some 80 grit sandpaper.

I kept a bit of return edge on the top and bottom of the biceps.

Top:


Bottom:


Here is the front facing seam.  It’s really hard to tell in the picture but I think it turned out pretty good.


TL;DR

I trimmed and sanded the biceps.

[daryldoak]

Anyone else’s kit have this on the right outer bicep?



It will be covered by the overlap, but just curious.