In Star Wars Legends, Jes Gistang is a female Stormtrooper. Her armor is cut differently and designed to fit a female. Replica Props Forum user oota goota decided to work on a Jes Gistang set of armor after seeing a collectible of the character. He’s still working on modifying it, but his first stab at the armor is pictured above. Some of his notes about the build.
The chest plate and backpack are direct sculpt into plaster forms. I mainly used a belt sander to sculpt with! Ha ha! Ok so yeah the backpack details are wood and resin bits.
The ab and lower back bits are a wooden base with resin and bog details. And the butt and groin are plastic again. The good thing about this approach is that the thing you are making is the form you use for vac forming, no transition molds and no casting. the down side is it’s easier to stuff up the dimensions and there can be a bit of back and forth till you get the forms right.
He also modified a Stormtrooper helmet so that it wouldn’t like a big bobblehead on top of the modified armor:
So I had an old casting that I was able to hack up a bit and add a cut down bucket. I’ve only modified one side of the faceplate and need to shorten the lower jaw a bit but here’s my rough concept. Here’s a WIP I’ll try and put it next to a tk bucket for comparison later on. I’ve scooped out the cheek on one side a bit like a clone helmet and a bit like the JG statue just to see what it looks like and you can see the electrical tape holding the two halves of the cut down bucket together
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