Many Questions From a New Guy Regarding Making a Suit

[Brodoin]

Hello, I'm attempting to get into making my own Royal Guard suit but I have many questions. I'm making this thread because several of my questions are specific and it'd just be easier to post them all in one place rather than separate threads or searching the forum only to find my question is not answered.

Anyway, like I said I'm attempting to make my own Royal Guard suit. I am hoping that I can make it acceptable to join the 501st, though that is more of an "optional objective" to making my own suit to wear to conventions and special occasions (plus it'd just be cool to have in the house). I'm hoping to have this whole thing done for $250 to $300 or less, though I am willing to spend a little more if necessary. Either way, please keep in mind I'm hoping this will be 501st worthy.

I am planning to make an Attack of the Clones version suit. I'd prefer a Return of the Jedi version, but because I am left handed I'd much rather have the option to hold the Force Pike in my left hand. At least when not taking pictures. My choice in Royal Guard version is primarily for comfort.

Okay, here are my questions formatted into each part of the suit.

1) The Helmet

1.1 - A friend of mine has suggested using Pepakura to creat my helmet. Is this a good method of creating your own helmet?

1.2 - My head is larger than average. Using Pepakura how would I go about making the helmet able to fit my head comfortably without making it look weird and out of proportion?

1.3 - What would I use for the visor?

1.4 - What is the best color and brand of primer, paint, and gloss to use that best matches the cloak?

1.5 - Speaking of Pepakura, does anyone have a good file of the helmet I can use to create the Pepakura?


2) The Cloak

2.1 - Obviously the outside of the cloak is red/crimson velvet which I have found here: http://www.syfabrics.com/View.aspx/Plus ... et/689/264
And also here: http://www.distinctivefabric.com/velvet/velvet1.html

I also know the inside is lined with a burgandy cloth. My question is what should the lining material be? Is it more velvet or cotton or some other material? Also, is there a perferred supplier?

2.2 - Are there any guides to assist in making the cloak, as well as the inner robe? My mom has experience crafting clothes and has agreed to help me in this regard and I know having a guide to know where to cut and stitch will help greatly.

2.3 - I am 6 feet, 2 inches tall (188 cm). Assuming mistakes may be made, how many yards of velvet should I expect to buy?


3) Inner Robes & Sash

3.1 - What material should the robe be made of?

3.2 - As with the cloak, how many yards of the material suggested should I expect to buy?

3.3 - Is it possible (and acceptable) to make the sash be able to be tighter?


4) Gloves

4.1 - What is the most suggested store (online or physical) to buy the correct suede gloves?


5) Boots

5.1 - I wear a 10.5 wide shoe, so I'll need to wear a wide boot. Would this boot be acceptable? http://www.exotichighheels.com/captain-108.html
I realize it has the lip at the top, however it is the only wide boot I have found thus far and I figure since the majority of it would be covered by both the robe and cloak I figured it would be fine.

5.2 - If the above boot is not acceptable then what are some suggestions to find one with the same size at a similar price?


6) Weapons

6.1 - Are there any supplies that sell acceptable pre-built Force Pikes for relativly cheap?

6.2 - If the above is false or in doubt, then are there any good guides to creating a homemade Force Pike that isn't too hard for a first-timer made from relativly cheap materials?

6.3 - Are there any decent guides easy enough for a first-time to create a blaster pistol from either an existing toy or from cheap materials?


I know this is a lot of questions and I appreciate everyone that takes the time to answer, whether you answer just a couple or all of them.

[LuciousTalvloinne]

Hello, I'm attempting to get into making my own Royal Guard suit but I have many questions. I'm making this thread because several of my questions are specific and it'd just be easier to post them all in one place rather than separate threads or searching the forum only to find my question is not answered.

Anyway, like I said I'm attempting to make my own Royal Guard suit. I am hoping that I can make it acceptable to join the 501st, though that is more of an "optional objective" to making my own suit to wear to conventions and special occasions (plus it'd just be cool to have in the house). I'm hoping to have this whole thing done for $250 to $300 or less, though I am willing to spend a little more if necessary. Either way, please keep in mind I'm hoping this will be 501st worthy.

I am planning to make an Attack of the Clones version suit. I'd prefer a Return of the Jedi version, but because I am left handed I'd much rather have the option to hold the Force Pike in my left hand. At least when not taking pictures. My choice in Royal Guard version is primarily for comfort.

Okay, here are my questions formatted into each part of the suit.

1) The Helmet

1.1 - A friend of mine has suggested using Pepakura to creat my helmet. Is this a good method of creating your own helmet?

This a different medium to use verus the resin or fiberglass options. This method will take some time and such as you will need to cut out the pieces and then bondo and sand until all the sharp edges are gone.

1.2 - My head is larger than average. Using Pepakura how would I go about making the helmet able to fit my head comfortably without making it look weird and out of proportion?

There is a scaling option in pepakura to scale it to your head size

1.3 - What would I use for the visor?

Visors can be Red Plastic, Black Plastic or Red Mirrored Plastic Lense. These are often the football inserts

1.4 - What is the best color and brand of primer, paint, and gloss to use that best matches the cloak?

Primer is normally just a grey or such. - Paint depends on your location what your market will be for it. You can use gloss. When I did mine I used a matte and just kept wet sanding over and over then repaiting and wetsand some more.

1.5 - Speaking of Pepakura, does anyone have a good file of the helmet I can use to create the Pepakura?

I should have access to one of the Helmet styles.


2) The Cloak

2.1 - Obviously the outside of the cloak is red/crimson velvet which I have found here: http://www.syfabrics.com/View.aspx/Plus ... et/689/264
And also here: http://www.distinctivefabric.com/velvet/velvet1.html

I also know the inside is lined with a burgandy cloth. My question is what should the lining material be? Is it more velvet or cotton or some other material? Also, is there a perferred supplier?
The inner fabric is Gaberdine

2.2 - Are there any guides to assist in making the cloak, as well as the inner robe? My mom has experience crafting clothes and has agreed to help me in this regard and I know having a guide to know where to cut and stitch will help greatly.

2.3 - I am 6 feet, 2 inches tall (188 cm). Assuming mistakes may be made, how many yards of velvet should I expect to buy?


3) Inner Robes & Sash

3.1 - What material should the robe be made of?

Gaberdine fabric with The same fabric used for the sash and obi

3.2 - As with the cloak, how many yards of the material suggested should I expect to buy?

3.3 - Is it possible (and acceptable) to make the sash be able to be tighter?

My sash is done with velcro so it lets me adjust the tightness depending on event and time of year.


4) Gloves

4.1 - What is the most suggested store (online or physical) to buy the correct suede gloves?


5) Boots

5.1 - I wear a 10.5 wide shoe, so I'll need to wear a wide boot. Would this boot be acceptable? http://www.exotichighheels.com/captain-108.html
I realize it has the lip at the top, however it is the only wide boot I have found thus far and I figure since the majority of it would be covered by both the robe and cloak I figured it would be fine.

These would be fine

5.2 - If the above boot is not acceptable then what are some suggestions to find one with the same size at a similar price?


6) Weapons

6.1 - Are there any supplies that sell acceptable pre-built Force Pikes for relativly cheap?

A cheap home improvement store pike can be made for around $40.

6.2 - If the above is false or in doubt, then are there any good guides to creating a homemade Force Pike that isn't too hard for a first-timer made from relativly cheap materials?

6.3 - Are there any decent guides easy enough for a first-time to create a blaster pistol from either an existing toy or from cheap materials?

Hasbro made a NERF DH-17 years ago. Some paiting and basic mods can be made to make it more screen accurate.

I know this is a lot of questions and I appreciate everyone that takes the time to answer, whether you answer just a couple or all of them.

[Brodoin]

Thanks for the info.

I read you can use fiberglass resin to cover the Pepakura which would make it much stronger, as well as using fiberglass cloth on the inside under a layer of the resin. While I'd need to spend a little extra to buy a good chemical respirator mask, I think I'd like to go this route to ensure the helmet lasts as long as possible.

Also, I have found some mod instructions for the DH-17 and I've been looking to find one online. Unfortunately they are hard to find now-a-days, it seems. Only one I've found so far is $80 on eBay.

[Brodoin]

Would a good cloak design be like: the front part would be a separate piece that is sewn into the back/shoulder piece starting at the shoulders up to where the neck halves meet. It seems like the most simple design choice.

[LuciousTalvloinne]

This would be one of the few pictures of the "RED GUARD"

[JesterTDA]

I'd highly recommend against the pepekura route for the helmet. The time and effort for something with so many complex angles is insane. You can find helmets for around $250ish which I know isn't the same as a coffee but it's worth it. I made one for my 8-year old son for Halloween this year and while it wasn't difficult I couldn't imagine making it smooth enough:



Painted with gloss paint (didn't resin or anything)


While I'm not saying it's impossible, I am saying it would be crazy difficult I think. Just my 2 cents. That being said my 12-year old is going to work on Halo Spartan armor this summer which we do hope to resin/fiberglass. I've seen those work out and look great and they have some complex angles so I guess it can happen.

[lilfear1]

I thought the boots had to be red???

(Quote) 5) Boots

5.1 - I wear a 10.5 wide shoe, so I'll need to wear a wide boot. Would this boot be acceptable? http://www.exotichighheels.com/captain-108.html
I realize it has the lip at the top, however it is the only wide boot I have found thus far and I figure since the majority of it would be covered by both the robe and cloak I figured it would be fine.

These would be fine

[Brodoin]

This would be one of the few pictures of the "RED GUARD"

This is what confuses me. That image seems to indicate that the cloak is a front and back piece with the shoulders overlapping to create the arm slits. I've seen in other images, though, where the cloak is more like the ROTJ cloak but with an arm slit on both sides and the seams being on the shoulders. Like this: http://img2.wikia.nocookie.net/__cb2013 ... eptart.jpg

I'd highly recommend against the pepekura route for the helmet. The time and effort for something with so many complex angles is insane. You can find helmets for around $250ish which I know isn't the same as a coffee but it's worth it. I made one for my 8-year old son for Halloween this year and while it wasn't difficult I couldn't imagine making it smooth enough:



Painted with gloss paint (didn't resin or anything)


While I'm not saying it's impossible, I am saying it would be crazy difficult I think. Just my 2 cents. That being said my 12-year old is going to work on Halo Spartan armor this summer which we do hope to resin/fiberglass. I've seen those work out and look great and they have some complex angles so I guess it can happen.

I've found some builds online where the person made a helmet using Pepakura with fiberglass resin and it ended up looking very professional, so it is possible. If I am remembering right one did use a Pepakura model with lot of pieces to make it as smooth as possible, and what wasn't smoothed was made smooth using sanding after the resin hardened. I assume you could do the same with just about any model. It may be a bit difficult but I don't think it'd be any harder than any other homemade armor project I've seen.

I've also seen some that use the fiberglass and resin for strength and then sand down the sharpest edges, but then use bondo to cover up the rest and make it smooth..

[Brodoin]

Would this be a good fabric to use in the cloak lining and robe/sash?

https://www.fabric.com/buy/0269372/cott ... gQod9xoAqw

[LuciousTalvloinne]

Would this be a good fabric to use in the cloak lining and robe/sash?

https://www.fabric.com/buy/0269372/cott ... gQod9xoAqw

Twill Is fine for the underrobe and Sash.

ROTJ = Imperial Guard Red Red Suede boots
AOTC = Red Guard Black Jack Boots
ROTS = Imperial Guard Red Suede Boots