Engineering Trooper’s Death Trooper build WIP

[Engineering trooper[TX]]

So after 5 years since I got the kit, finally started work on my Death Trooper.  My thanks to Gerald (Doggy Doc) for getting me motivated, and getting probably months of work done in one day!   
 

It’s an old kit, unsure of the maker, bought it second hand back in 2020.  It took us  a bit just to identify some of the parts are a mixed lot, Armour being ABS, some parts resin, others early 3D printed.

Some points about the kit: 

1.  The  kit came with a 2 piece under-suit, ribbing integrated into the suit.  Unfortunately it seems incomplete and does not fit.  
If anyone has suggestions as to where to get a good under-suit/gaskets, would appreciate it.

2. Shoulder straps are resin, and integrated the vent openings that would normally be part of the back plate armour.   More on that in another post…

3.  Thigh pieces had separate ribbed strips made of ABS that would need to be added in. Unfortunately, they don’t meet the rubber like criteria description per the CRL, but in any case won’t work because 3 of the 4 pieces are larger size, so mismatched .  More on that in an upcoming update.  

4.  Left forearm pieces did not have the 2 rubber straps or buckles included.  Gerald sent me information on a pipe gasket I can slice up for the bands but not sure where to get the buckle info.   If anyone has a 3D print file of the left forearm wrist buckles, could appreciate any information. 
 

5.  Boots are Doc Martins, so according to Gerald,got lucky with those.  
 

6. Shins will need cover strips, Gerald sent me  some measurements from his kit, will need to cut those separately. 
 

7.  Thermal Detonator is 3D printed.  Gerald noticed that both end caps are same size ( about 55 mm diameter), but one should be different size (smaller/bigger?).  Any information would be appreciated  

 

8. The kit came with 2 trapezoidal pieces, which we identified as being the bridge pieces between the chest and back plate armour  

 

9.  Could have the separate back pieces are resin, including the cog.  Mine is a floating piece, 15 points(not the 16 required for level 2).   If anyone has a file for the cog with 16 points and the integrated p,ate, would appreciate any help with it..

10.  Included a vinyl ribbed belt, which seems to fit the CRL requirements.

11.  Gloves were good, had integrated Velcro patch on them, so only needed to add it to the armour plates.  
 

 

12.  Kit came with belt boxes (3D printed), and pouch parts for the canvas pouches (ABS).   Gerald provided me with a pattern for the canvas pouches, and a link to Nanotek’s holster pattern. Leather pouch will be another issue.    More to come there also..

13.  D rings and ejection seat buckles for front chest plate are resin.  They are ok, but would like to replace them if possible.   Any information on sourcing other parts, or 3D print files would be appreciated! 
 

14.  The kit has a few 3 d printed solid blocks, think they are to be used for the ammo belt  on the left thigh.   No way to attach them directly. If anyone has any information, or better files/parts that are available would be appreciated.  

 

Helmet is Anovos, bought about the same time as the kit.

The kit came raw, untrimmed.  Gerald helped me get all the pieces trimmed done and ready in one afternoon!  The guy is amazing with a belt sander, each time getting it down precise  even depth.  His expertise on the build is amazing, helped me make some sense of the kit, as being an older version, some pieces were hard to identify.   Could not have gotten this far without him! 

He also provided some information on how he strapped his kit, so I started making snap mounts and will start strapping soon as Iget a better handle on the kit as a whole . 

I will attach pix of  armour pieces, undersuit etc once I am able to downsize my pix on the computer  

More to come as I progress.  In the meantime,  any help with sourcing, 3D files or general information would really be appreciated! 

Jim 

 

[Engineering trooper[TX]]

Some other pics  including   thigh ammo boxes, , misc pieces, undersuit top and bottom with integrated ribbing, boots, thigh ABS ribbed pieces, and 3 d printed thermal detonator. 

 

 

 

 

 

 

[DoggyDoc[CMD-DCA]]

Hey Jim,  good to see you starting a build thread.  I can set you up with all of the buckles and will see what I can do for the forearm strap buckles.  If anyone has a 3D print file to save me rendering it, that would be great.  It was fun getting back to trimming armor pieces again.  

 

One thing you may want to do is use imgur for your photos.  The forum has very limited space for photo uploads.  just create an account and upload the images there.  when posting on the forum, just paste the Direct link into the message and the photo will show up.

Looking forward to getting you out there trooping with us as a death Trooper.

 

 

[Engineering trooper[TX]]

Thanks for the info Gerald,  appreciate all of your advice and help!

Currently have made some progress, 

1. Am in touch with Geeky Pink, sent my old under suit to her to review,  not salvageable, but at least she can look at it as reference of older type.  Hoping to hear from her in next month or so for availability of an under suit.

2. Glove plates are mounted

3. Strips cut and glued for the biceps

4.  Tried previously to put together the E-11 D 3 d print kit that came with the package, but it's missing parts.  If anyone has the files, would appreciate it, as not sure what parts are missing.   See pix on what I've pieced together thus far.

5.  Separated the straps from the vent, so will be able at some point to glue those directly to the back armour.

6.   Decided to try to  make a mold  of the ABS thigh side panels I have and cast them out of a flexible rubber.  Will be first time trying, so should be fun!

7.  My wife will be helping me to do the canvas pouches, using Gerald's pattern.  Hopefully will work out.

8.  Bought the rubber coupling part that Gerald indicated would work for the left forearm bands from Home depot. 

More to come as I progress.  Probably will mount some of the snaps this weekend, and do cover strips for the forearms and calves.  

 

Added some links to the Imgur images, can't seem to get the link to image to work directly in the text.

 

https://imgur.com/RgUW2Mb

https://imgur.com/CVaynPN

https://imgur.com/1HeKao3

https://imgur.com/06yxRA2

https://imgur.com/OvzRAu2

https://imgur.com/fBKEaN0

https://imgur.com/y3vVQ8b

 

Edited July 16 by Engineering trooper
Added Imgur links

[DoggyDoc[CMD-DCA]]

Hey Jim. 
 

if you past the direct link, instead of just the link, onto the page, the photo will show up

[dogbertwrldrulr[TX]]

4 hours ago, Engineering trooper said:

 

https://imgur.com/RgUW2Mb

https://imgur.com/CVaynPN

https://imgur.com/1HeKao3

https://imgur.com/06yxRA2

https://imgur.com/OvzRAu2

https://imgur.com/fBKEaN0

https://imgur.com/y3vVQ8b

 

On the Imgur links, right click the picture you want to bring in and click "Copy image address".  See image below.  Once you paste the link, it should immediately show in the reply editor.

[Engineering trooper[TX]]

Sept 07 2025: Long awaited update.  Been a few months, but made a lot of progress, especially with Gerald's help.   We did a rough fitting back in July, and with that I had a lot of follow up work to do, including molding parts, some trimming and gluing.

1. At this point, the main torso is in good shape, adjusted the strapping and did some cutting on the ab plates per fitting at Gerald's.

2. Did some molding, trial and error as I unintentionally used the parts material (Smooth on 121/30) for the actual mold, and the Smooth on 30 as material for first run.  Mold turned out good, but when I added in the colouring material to the 30 material, turned into goop.  Seems I misread my instructions.  Long story short, did other molds with the proper mold 30, and ended up switching to a harder durometer rubber (Smooth-On Econ 60) for the parts.    Parts turned out pretty well.

3. Gerald kindly 3 d printed me some of the D clips and other parts out of a stronger material (forget what it was), and I was able to add the D clips into the mold to so to get the rubber portion of the side trapezoidal straps integrated.  See pix, turned out really well

4.  Glued together the forearms, so far so good.  Will add the wrist rockets (Phoenix Props) and rubber straps (850 Armorworks) after getting everything fitted and painted.

5. Started work on the thighs to glue parts of them.  In our second armor work day, Gerald hacked a lot off of the thighs, seems I wasn't as tall as the original model it was designed for   .   At least I have a lot of spare ABS for slurries ..

6.  Am working on the shins today, lot of hit an miss with the covers strips, but with a lot of glue and clamps am getting there.

7.   I ended up redesigning the end caps for the thermal detonator that came with the package.  Gerald indicated that to meet level 2, one cap had to be longer than the other (approx. 13 mm versus 19 mm).  So with Tinker Cad and my trusty old Prusa, was able to make those.

8. Bought some parts/kits from 850 Armourworks, including replacement thigh bricks (ones in the kit were not great prints), wrist straps, and leather pouch/holster kits.  Pouch and holster kits need assembly and snaps, so will see how those work.  As it is pretty thin leather, I will probably opt to make my own holster using thicker leather and the drawings provided  to me by Gerald.  More to come on that progress

9. For my shoulder straps, as mentioned I made a mold, as the original parts were resin (and connected to the armor vent parts, had to Dremel them apart).  After experimenting with 2 different Smooth On materials,  Econ 60 is the better choice, much stronger).

10.  Asked one of my friends in the garrison who does machining to try to make me a belt buckle out of aluminum.  He has my 3 d part, so will see how that goes. 

11.  Readjusted the side trapezoidal pieces, Velcroed them to back plate, and will glue to front as part of fitting so to see how to cover that portion with the D ring/trapezoidal straps. 

See pix attached.  Thanks to Gerald for all of the help, (and great fitting pix).

So next steps are to get my undersuit from Jim Tripon,  some fitting, coverstraps and finish on shins, working on adding in the rubber parts on the thighs.  Lots yet to do, but getting there!

 

 

 

[Chaos[CMD-DCA]]

Excellent progress!

Sounds like you are eventually going to go for L2, if that is the case, once you perfect your shoulder strap mixture, try and find a mold that has the curvature required for the shoulder straps "Shoulder straps will be rubber with the same appearance as basic, but they will also have a slight inward angled curve following the shape of the neck opening."

Also keep in mind, the thigh rubber gaskets are different widths.

• The ribbed infill shall be made of black rubber, or a semi-gloss black material, or if part of the thigh pieces, have the appearance of being rubber or rubber-like material.
• The inside thigh ribbed section is wider than the outside ribbed section.