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Resistance Trooper Build - TFA & TLJ

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stugpanzer (David Kurtz)
Active Legion Member

Joined: 25 Sep 2017
Posts: 133
Location: Sandwich, IL
Medals: None

PostPosted: Wed May 01, 2019 3:03 am    Post subject: Resistance Trooper Build - TFA & TLJ Reply with quote

When I saw Force Awakens I loved the new Resistance Troopers! I then embarked on building my kit.

This is what I came up with:

I needed three items that I couldn't find. The unique helmet which has a flip-up jaw and in some scenes in the two movies some even have the jaw removed. The other is the EL16-HFE Blaster which is what we see Finn using. I noticed there were two variants of that blaster. One is a rifle with a stock and one is a 'carbine' without the stock. Finally I needed a custom bandoleer.

I used movie reference pics such as these:

As well as Battlefront II In game captures:

...and even an action figure reference:


Now for the sources for the entire costume....

The boots:

Amber lense for the Helmet:

Pants (Slacks):

Helmet Padding:

For the 3d printed parts, I reached out to a designer i found out on Thingiverse and approached him to see if he was interested in designing this helmet. After some discussions he and I came up with an arrangement where he and I would collaborate. He designed and I printed, test fit, then critiqued, then he would make adjustments. I also tipped him for his expertise along the way. While working the helmet after some more discussion it turns out that thois designer was really keen on designing blasters so I added a request to design the EL16-HFE blaster.

The designer is Jaedon Tseng and his design studio is called Open Chest Design. You can find his designs here:


And the EL16-HFE Blaster:

Jaedon is a great person to work with and very talented! I highly recommend him for any custom 3d designs!

I also needed a custom bandoleer. This one is unique and so I reached out to Delta Leatherworks, Michal Konopinski to design the leather. Some of you may know him! He is well revered for his work among all the Star Wars (and others) Costume clubs. Another very talented person and if you are looking for custom leather of anything, this is your man!

Resistance Trooper Bandolier:


The Build:

After the designs for the helmet and blaster were completed, I printed them. I found that (for my head) I had to reduce the helmet down in scale by 5% other wise it was way too large.

Here are a couple prints of the helmet print in progress:

I printed many iterations until I got to that last one!

I also printed the concern of color as I will be painting it:

The unique feature of this blaster and a request from me was to make the stock removable. Jaedon created this spring loaded, 3d printed release:

For painting the blaster, I took the stock STL file and I cut it down and added a cylinder that would fit into a 3/4" PVC pipe so I could set it in that pipe and paint it:

As for what paint I used, I will need to come and update this section with that detail....

>>>>>>>> I will stop for now (getting late) but I will come back very soon to finish this tutorial <<<<<<<<<<<<<
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