Darth Dog's ROTJ Royal Guard WIP

Post by **Darth Dog** » Mon Apr 20, 2015 8:32 pm

I have been thinking about cutting the 1st pike I made in half and installing a nut and bolt setup to allow for easier storage and transport. One of the coolers I ordered arrived yesterday. Now to work on the hose connection from the cooler to the helmet.

Post by **Darth Dog** » Tue Apr 21, 2015 10:01 am

Recently received my 2nd cooling unit. The 1st worked once and wouldn't do anything after that. I returned that unit and ordered a second (on Amazon) which was shipped from China and took a month to arrive. It seemed to be working fine but once again stopped working. Since it was cheap ($14) and took forever to get here I decided to operate and see if I could locate the issue. It has a stupid rotery off/on switch and the switch seems to be the issue. I plan to dig up a simple slider switch to replace the original with. There is also a circuit board for the alternate power cord which will not be used. I plan to remove all that and just have the batteries, switch, and fan. K.I.S.S.

Post by **V-cell** » Sat Apr 25, 2015 4:19 am

Air circulation becomes a big issue with our buckets. It would be great if you could post your "cooling" system for all to see. Thank you for your tutorial on the forcepike, a beautiful and amazing work of craftmanship!

Post by **Darth Dog** » Sat Apr 25, 2015 4:32 am

I'll post some pics once I start doing something but it is going to be the same type as used in the thread "My bucket is air conditioned". I'll post pics of my switch replacement as others may run into the same issue with the unit. It seems to produce good airflow.

Post by **Darth Dog** » Mon Apr 27, 2015 9:57 pm

Changed out the switch in one of the coolers today. Took about 30 minutes. The original switch was a crappy rotary switch that wouldn't work because it was failing to make contact. The 2nd cooling unit also seems to have this issue. I bought 5 slide switches at the local hobby shop for around $5. There was a small circuit board that is associated with the usb power source. As there will be no need for that I took it out and wired the new switch between the fan and batteries. Had to make the opening for the switch a little bigger and drilled a couple of holes so I could secure the switch with screws. Now the fan works fine. Next I'll attach a mounting clip and the vent hoses to the unit.

Post by **Darth Dog** » Mon May 18, 2015 8:00 am

Our helmet has just been pulled from the mold. Some clean up, sanding, and primer and it should be in the mail.

Post by **Darth Dog** » Thu May 28, 2015 12:55 am

Robes in route from FP. Maybe in about 3 weeks we'll have it here.

Post by **LuciousTalvloinne** » Thu May 28, 2015 4:05 am

Looking Top Notch. i GOT ONE of those helmets.

Post by **Darth Dog** » Fri Jun 05, 2015 11:01 pm

The soft parts have just hit Miami today. Am expecting delivery around the later part of next week. No further word on helmet.

Post by **Darth Dog** » Wed Jun 10, 2015 7:30 pm

Robes arrived today. Wife tried them on quickly but no pics. Fit seems pretty good. Don't think I will have to hem them. Not wild about the belt. It is just a strip of cloth that is to be wrapped around and as such it wants to wrinkle. I think I will find something to stiffen it, fold it in half and sew the stiffener inside and use Velcro to latch. Should produce a flatter surface. Thoughts? Should be able to get pics soon. Helmet still out there somewhere.

Darth Dog's ROTJ Royal Guard WIP

The Imperial Royal Guard costume as seen in Return of the Jedi

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