Updates, and News
[Update 12-APRIL-2008]

Just a short update to include the assembly guide for the Commando Blaster Kit. These have now sold out, but if there is interest I'll do another run. My molds are pretty beaten up but I think I can get maybe 5 more sets. The Bandoleer kits are almost gone, and these too will require new molds if there is any interest in doing more.

Updates, and News
[Update 31-MARCH-2008]

I'm cleaning out the storage room, and many of the projects are now listed on the catalog page. I'm sad to let them go, and many of these items are very limited in numbers.There is a Rebel Technician helmet kit:

And a link to the assembly guide. Also, I made some Endor Blaster kits:

Click here for the assembly guide. And finally, I've been asked to help the Sunrider Base out with some bandoleer Greeblies:

And the bandoleer assembly guide.

Updates, and News
[Update 28-FEBRUARY-2008]

Due to some heath concerns, and too many projects in the works, I'm taking some time off. Working three jobs, a wife and two kids, and a house expansion project that will take most of the Spring, I'm just not finding enough time to work on all the projects I want to. So, as a result, I'm wiped out. I stay in a state of chronic fatigue. I've developed an alergy to the casting resin used for the blaster parts. As a result, when the current batch of parts is sold out, I don't plan to make any more until this Summer at the earliest. Hopefully this will give my body time to recover. The hiatus from prop making I hope will be a short one. The RFt helmets and kits are all but gone, and when my current supply of plastic and parts is gone, I don't expect to make any more until this Summer. The fan film is on hold until June/July as well.

Updates, and News
[Update 11-FEBRUARY-2008]

Wow, it's been a long time since my last update. I've been really busy with life and work, so not a lot has been going on with the replica props, or the fan film with a few exceptions.

The Endor Commando Blasters are coming along. I sent a sample out for inspection, and with only a minor change, these are nearing the production run. Yea! I'm making a few to help out some folks, and when these are done, I'll add some to our sinper arsenal. The remainder will be available for sale as an advanced modeler's kit. The run will be limited to 20 kits, and 10 are already spoken for.

Next up, is the Rebel Tech helmet, as a special request, I've been asked if costumers could get just the shell, comm box, and chincup with strap. Soon, these Reb-Tech kits will be availalbe, as well as the individual RFT helmet parts. The supply of finished helmets is gone, and the kits are almost sold out, so this is a way for me to sell off the remainder of my inventory. Also, the catalog page has gone through some changes, some items are sold out, and others are new. The grip/trigger assembly and the magazine blocks are sold out. Email me if you think I should do another run of these two parts.

The fan film is on winter hiatus, pending some upgrades to the trooper arsenal, specifically the T-21 'Lewis Gun' blaster, and the crashed X-wing pilot costume.

Oh, and once last thing, this Summer will mark the 5th year www.tk560.com has been online! Look for some special announcments very soon.

Updates, and News
[Update 20-DECEMBER-2007]

Lots of updates, but I'l try to make it short. I've been working on an Endor Blaster A281 as part of the sniper corps for our fan film, and as part of a project with another Rebel Legion group. The idea was to make a cost effective blaster, something lightweight pretty simple to build. I started with a Well Fire based spring fire AR15/M16, removing the unwanted parts, and make custom replacment parts as a dress-up kit. Below is the prototype:

Click on the image for a larger view. Email me regarding this project. We have also been asked about a Rebel Tech helmet, and yes, we can provide these and will include a few in our film if we get the hangar shots we need. We will need them. A good addition, and is basically an RFT helmet with the visors and swoop removed. And along these same ideas, I worked up another helmet based on the WWII Navy Talker MKII helmet, the basis for the RFT helmet. The Imperial Death Star Gunner helmet! Not sure how we can work that into the film, but it was an easy helmet to make and Mom wore it on Halloween!

The CGI artist, David A. has been busy with the space shots, and even some bluescreen work. The results are looking great. Check out the fanfilm page for updates and links to an FX reel.

Updates, and News
[Update 21-SEPTEMBER-2007]

During the break in August, Herb and I had a chance to scout a location and do a test film of the now 'infamous' water scene. Honestly, it did not turn out the way I wanted. A new location may be in order. Part of our problem is access to a local lake, and then access to an appropriate beach. One that has the right depth, and bottom, one that we can trot our equipment to and from. We did shoot some footage, but with one trooper, and the water was rough, and as a result, the footage is not what I wanted. You can see a sneek-peek of the footage on the Fan Film page.

We also had a chance to film some blue screen test, and I will be posting the results in a few days. No fan film material, more of a proof of concept. We did the chroma keying using both Adobe Premiere, and with Final Cut Pro. FCP is a better final result, even with an older copy. Things learned, you need a pretty good camera, and perfect lighting. Next thing to test will be some scale models shot. We have an Imperial Shuttle that we will try and shoot as a blue screen shot.

Planning is key to good blue screen work. A digital matte, and some live action along with a scale model, all in the same shot. Thats the next attempt.

On the prop/costume front. Bad news. During the recent wet weather here in the Piney Woods, the MDF molds in my shop got wet. Most of my trooper armor molds got damaged. I think I can repair them, but honestly, I don't know when I'll get around to rebuilding them.

The Death Star Gunner helmet project is a go. Looks like I can use my RFT molds, some smoke acrylic, and one new part, pull these parts in black HIPS, and have a good looking Gunner's helmet. I even plan to get some decals made in vinyl. This makes a nice addition to the Imperial forces, even though we will only see him at the very end.

An Imperial Fleet Trooper helmet is also in the works, but requires a couple of ear molds to be made, and new swiss cheese visors. Not sure how I want to handle these, yet.

The X-wing pilot/TIE pilot helmets and costume projects are on hold pending me finishing the new sculpts of the helmet shells. I'm about 60% done with the masters, and this time, to avoid the issue with the MDF getting damaged, the master patterns will be duplicated in a special resin made for vac-forming. More on that as I get these molds done.

I had some issues with my ISP and my catalog page. All seems to be working now. Sorry if you tried to order something and could not. Try again now, and let me know if you have any issues.

Updates, and News
[Update 27-JULY-2007]

Just a minor update. The RFT belt boxes are done! Below is a pic of the prototypes on a Tandy leather belt. For more details on the boxes, check out the Fleet Trooper page. The RFTs needed a bit more detail on their costumes, and these boxes do the trick. I'm also working on some hero comm boxes with the antenna, smoke actylic visors, and holsters. These added 'hero' details will help us flush out this costume to the max potential. The devil is in the details.

We now have access to a new camera, an XL-2 that can shoot in 24p, 30p, and 60i mode in both 4:3 and 16:9 aspect ratios! We also have access to a new wide angle lens. I'm working on a gib/crane and mic boom as well. A lake location test is on schedule, and I hope we can get some good footage soon.

2012 is on hold pending more script work, and a new short my be in the works. Details to follow soon. A new project is in the works, code name 'Sandman'. Details soon!

Here is the belt boxes:

Donut is complete! Here is a pic of the ready to paint sample:

Email me for details.

Updates, and News
[Update 13-JUNE-2007]

Some clean up on the main page. This is way over due, so some articles have been moved to more their proper places. Also, some dead links have been deleted. New Legend the movie, is now moved here. The Last Garrison fan film info can be found here. In addition, I've moved some other links and images around, to help load times.

A new mold is in the works, this time, for our Endor Commando donut. In our fan film, the Commando costume is our sniper. Click here for some sneek peeks at the mold making process.

Top section of the donut, almost done.	Test fitting the bottom section.

Updates, and News
[Update 12-MAY-2007]

'New Legend' an 'I am Legend' fan film has a new home.

Recent Updates, and News
[Update 26-February-2007]

Filming on the 'New Legend/I am Legend' fan film has started. As soon as I get some cllips or still of the footage we shot, I'll get some posted. Clint H. is working hard to get this ready for filming in the coming weeks, and even has a house located for the 'attack' scenes, and interior shots.

The fan film, 'The Last Garrison' is still in development, with some behind the scenes work being done. We now have a minature of the Imperial Shuttle, and it is going through a weathering process, with some details being added to make it more visually interesting. Also, a new location for the bunker entrance has been found, with a pick-up shot to be filmed in the coming weeks.

I still have a couple of resin parts and RFT kits, but my supply is almost gone. I'm hanging on to a few spares for the fan film. Please email me if you have any questions. In related new, starting in March, Hasbro is suppose to be offering a DH-17 'Nerf' blaster, so a full review, and converison is planned. The only part of the RFT costume now giving us fits, are the boots. The East German boots from Sportsmans Guide are gone, but other surplus sources still have them.

New information regarding the CMP's M1 Carbine offering can be read here. And new information regarding the latest GIjOE action figures can be found here and here.

X-wing Helmet progress
[Update 25-Feb-2006]

I've been working for the past few weeks to get a X-wing helmet pulled together for the fan film. A sequence requires unarmed, hand-to-hand combat between a shot-down X-wing pilot, and a stormtrooper. The rest of the costume is progressing well, but the helmet has been giving me fits. The movie helmets were based off a Vietnam era US Navy flight helmet, the Gentex APH6-B. Sought after today by collectors, finding an original in any sort of conditon has been hard to do. I've been searching for several years to track down a couple for my collection, and each lead ended with disappointment. I can't afford $500 for a vintage helmet, one that I plan to make a replica movie prop from, so I started working on making my own. Progress is going well. I have a vacuum formed kit I got from a friend, that I am using as a scale guide. Several things about the kit. It has really soft detail, and that was one thing I have noticed with most of the vac-formed kits. I wanted to first get the shells done, then start working on the visor mold. If I can figure out a way to make the visor retract that would be great, but not required.

I now have the final molds for the chin cup, mohawk end, and I've started work on the visor and shells. The MDF sandwich method will only get me so far with this design, the rest will need to be build from bondo, and hobby board. For the most part this is a carve and sand project.

Not only do the exterior of the helmet need to be created, but some sort of internal ear cups, and headband suspension need to be worked out. Engineering continues...

Endor Command Sniper

We are adding yet another Rebel costume to the fan film, based on the Endor commandos as seen in Return of the Jedi. Design plans have been drawn up for the unique helmet, and blaster, and research is progressing on the costume itself. More details will follow.

Blaster's a plenty!
[Update 1-Feb-2006]

The Imperial Stormtrooper's standard E-11 blasters are done at last! Here are some of them I made for the fan film. These are PVC 1.25 inch water pipe, and my resin parts cast from my real dummy gun L2A3. Click on the image for a larger view.	Here is a shot of the real [IMA dummy gun version] and my prototype e-11 made with my 6-piece resin set, and some scrap material. That's a real M38 scope, and a real counter. The Grips are some I got online. Click on the image for a larger view.

Here is a pic of the resin parts I have, and what they look like mounted on a piece of PVC, primed and then finally painted: Click on the picture for a larger view.

E-11 Blaster Parts Kit [Limited Supply] Resin versions of the hard to make blaster parts The original plan for the fan film was to have 20 troopers in some large scale battles, much like that of the old WWII movies. I started making the blasters for the 20 troopers, then a production decision was made to reduce the number of trooper by half. So, I am left with a bunch of these resin parts, and if you need any let me know [email me]. These were made to speed up the blaster making for the fan film, and as a film prop, they do have minor air bubbles, and flashing that need to be cleaned up. An easy job for the scratch-built blaster project. These were cast from a real L2A3 Sterling, M38 scope, and counter box. [non-logo version]. Supplies are almost gone! Get them while you can! I don't plan to make any more. Please visit the Catalog Page for more informaiton.

Latest suits finished. TK560 [me] on the left and TK652 on the right. Click on the image for a larger version.

Build Your Own Stormtrooper
[update 5-19-05]

Back in August 2002 I started on a project; to create my own Star Wars Imperial Stormtrooper armor from scratch. Now, over 28 months later, and countless hours research, trial and error reverse-engineering and hard work, I finally have reached a point where, I have a complete set of armor molds made. This pic shows TK560, on the left, and TK652 on the right. The suit scales pretty well for a person from 5' 5" to 6' 2" [me].

What does it take to make a stormtrooper costume? Well, the process is a complex one but not beyond what a fan can do in his spare time, and a few square feet in the garage. The first step is the vacuum forming machine. I must have made 4 different machines before I got one lagre enough to pull this project. The second step is the molds. Different techniques have been used by other fans to make their trooper armor, but for me, I took advice from a fellow RPF board memeber, Phil G. aka Blaxmyth, and used MDF and Bondo to make the molds. The final step is to pull the plastic, trim out the parts, paint and add details.

Its been a long road, and the trip is still not over, but I can see the the light at the end of the tunnel! Click here for details.

Home Built Vacuform table #4.

This machine is the production version capable of making all the trooper parts, including the large chest molds and abdomen parts. It's powered by a 3hp shop vac, and a 30amp 110v heater.

Make your own Vacuform Machine
[update 3-29-05]

When I first got into building hand props, I soon realized several technologies would be necessary to make these props as realistic as possible: wood working, mold building, resin casting, white-metal casting, and vacuforming/thermaform would need to be mastered. From my old fine arts days, I could build the molds, woodworking was not a challenge because I have access to the necessary tools, and thanks to products like Pour-a-Kast, and RTV silicone molds, that part of prop construction was fairly easy. However, I wanted to be able to make parts like the shells of a Star Trek communicator, or the Tricorder among other items. This required me to construct a vacuform machine. Also, I wanted to make my own version of a Stormtrooper armor set, moulds and all so that I could build a SandTrooper garrison, for a fan film. I knew I would have to start out small. Do you want to know more about vacuum forming? Check out the video.

Tricorder prop replica

From Star Trek [the original series, 1966-1969], this is the first in a series of classic sci-fi props to be featured on www.tK560.com. Originally conceived by Matt Jefferies, and designed and built by Wah Chang for Pramount Studios to give Gene Roddenberry's new science fiction TV series, Star Trek, a "utilitarian" look. The replica here is as close to the original prop you are going to find. Straight from Roddenberry.com's online store, these $250 kits require several hours to build, but are worth every penny and every minute. Click here to see some more details on this truly outstanding prop replica. Unfortunately, Roddenberry.com no longer sells this great prop kit. Master Replicas now sells a "working" version. Get ready to crack open our piggy bank! Currently, I'm researching a way to add a working viewscreen using an old video camera. I have a 23 Century Science Recorder kit that just might work. Stay tuned for updates. Note, the backlog on props has increased! Now I have 4 phasers to make, 2 communicators to rebuild, a tricorder, Viper Pilot, and X-wing Pilot helmets, A complete Boba Fett costume, and a M41-a 'stunt' pulse rifle. Not to mention the vacuform machine and the stormtrooper armor!

Aliens Colonial Marine M41-A Pulse Rifle Prop Replica

From the 1986 James Cameron movie, Aliens. UPDATE: Project is finished. Man this the M41-A is a beast. It weights a ton. Biggest thing in my prop collection. Some fatigue in the shrouds has to be addressed, a resin pour to reinforce the shrouds will be required. Only thing left to do is add a real counter, but my "photoshop" version looks decent, and requires no batteries! There is a debate on the true colors of the shroud, so I went with an "idealized" color. The filming version were a bess brown, that in the lighting situations used in the film, appeared OD green. I have some spare parts, so if anyone is interested, please let me know. email me for details.

M41-A Pulse Rifle replica prop