You've heard about throwing away the supplied velcro, well this is true if you plan to wear your armour. You will need something that is stronger which allows the armour to move with your body. I created a system of heavy duty snaps and black elastic. The beauty of this system is that it is hidden and you can take the Armor apart for easy transportation.

Parts required

• Vario Pliers or use the plastic snap tool supplied with the poppers.
• ABS plastic sheet *Note (You can also use white ABS central heating pipe cover available from most DIY stores.)
  
• ABS Glue
  
• 2 boxes of '15mm Heavy Duty Sport + Camping Poppers
  
• Black elastic.(2m)

In the UK most of this can be brought from John Lewis's, Hobby craft or on-line at Venacavadesign
For my USA buddies try your local fabric store or Lowes or do a search on google for an online supplier for the pliers and snaps.

Step 1

 

• Drill a hole into a piece of 25mm by 35mm ABS plastic (part C)
• Place part A (Male) through the drilled hole of Part C
• Then place part B (female) the other side
• Now using the pliers or plastic snap tool create the male snap (part D)

Step 2

• Shoulder Bells, sand the area where the snap is to be applied, clean and then apply an even layer of ABS glue.
• Attach the snap (flat side down) to one of the shoulder bells, use a clamp to hold and leave to set overnight. Repeat for other shoulder bell .
• Warning ABS cement works by melting (welding) the two ABS pieces together, if you use too much, it will be visible on the exterior (be careful with this glue). Also do not put any ABS glue on the metal part of the popper or inside.

Step 3

• Biceps, sand the area where the snap is to be applied, clean and then apply an even layer of ABS glue.
• Attach the snap (flat side down) to the bicep (see photo for position), use a clamp to hold and leave to set overnight. Repeat for other Bicep.

Step 4

• AB Section, Glue two snaps flat side down at the top "inside" of the upper AB piece . Also glue a snap on the inside of the cod piece (see photo above for placement).
• Clamp these and leave to set over night

Step 5

• Kidney Section, Glue two snaps flat side down at the top "inside" of the upper Kidney piece . Also glue a snap on the inside bottom of the back (see photo above for placement).
• Clamp these and leave to set over night

Step 6

• Glue snaps in the middle under the connecting bridges on both sides. This is where the most stress will be put, so glue the snaps on well, try to glue to the raised ridges on the connection bridge.

Step 7

• Glue snaps in the top inside of the front of each thigh, clamp and leave to set overnight.

Step 8

• Wear the top armour (Chest and Back), measure a piece of black elastic that will reach from the connection bridge snap to the shoulder bell snap (mark where this on on elastic) and continue measuring down to the bicep snap (also mark where this is).

Step 9

• Allow a little slack for movement between the shoulder and bicep. Use the Snap tool and insert female poppers into each mark you made on the black elastic

Step 10

• Repeat last step (9) for the other side and connect the black elastic with the female poppers to the corresponding snaps on the armour as seen in the above photo.

Step 11

• You will now end up with an Armour T-Shirt. Notice above the elastic attached to the shoulder bells surrounding the biceps (marked by red lines), this elastic keeps the shoulders in tight against the biceps, I just glued these in place at the edge of the shoulder bell, ABS Glue should do the trick.

Step 12

• Abdominal/Back section - using 2 larger strips of black elastic, insert females poppers at each end and attach to the male snaps you ABS glued on the ab and back plate earlier. I normally cross these straps over, so they do not slip of my shoulders.
  

Step 13

• Wear the thigh pieces and any canvas or leather belt, (you can even make your own out of webbing and a buckle). Mark on the belt where the male poppers need to go. Using the tool insert the male poppers.
  

Step 14

• Wear the thigh pieces and the belt , measure by placing the elastic up against the snaps on the top of the thighs(according to what fits you) Once you have the measurements (distance from snap on belt to snap on thigh), cut 2 pieces of black elastic to length. These will hold the thigh pieces to the belt. Insert female poppers at both ends of the elastic.
  

Step 15

• You will end up with a belt with 2 thigh pieces suspended from it. Using this belt system makes it very easy to put on the armour on. (Below)The suspender belt method is how the thigh pieces were worn in Star Wars.
  

Step 16 - Finished!!!!

• Now put everything on and test the snap system, do a few poses, walk around making sure the snaps hold. If they don't hold you may need to adjust the length of the elastic. If it does hold, you got your measurements correct, welcome to the elite group of Stormtroopers :-)