PP2 Ord Mantell's PP2 Build

The Clothears suit finally arrived so I can proceed faster with this build.




First thing was to get the armor mounted. Which means taking a shotgun to the vest to get some holes in it. Make sure to get the special shot that spreads out in the correct symmetrical pattern.

Or the harder method is with the extra armor set with the holes pre-drilled... whichever makes you happy.


I might be done with this set now, so will have to figure out how we can pass it around if anyone wants to try it.

PP2 plates are spaced kinda wonky. Not like the hero suit.


I wanted to make sure the ab plate actually sits at the very bottom of the vest in order to replicate a unique feature of the PP2 vest.


Then mark the holes


So, very fast, let's take a look at that unique feature of the PP2 flak vest...

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The PP2 vest suffers from a little sag of the backing cloth. Now, unfortunately this led to a sad period in the history of our hobby where ppl misinterpreted what this was. People were seeing this as a hem stitch near the bottom of the vest, and so for a long time, people were making vests with a hem stitch along the entire front of the vest about 1/4" from the bottom. It was a very regrettable period. I tried to raise the alarm flag at the time but a fad is a fad. Sometimes its just unstoppable. Luckily its all in the past now and we can all laugh at the whole woeful affair.

I need to have this feature on my vest so thinking about how this happened, seemed to me two obvious possibilities. 1) the backside cloth was cut too long and simply hangs out. Or 2) when the grommet holes were punched in, the frontside and backside were just slightly out of alignment, with the backing just slightly further down and once the grommets went in, this misalignment became baked in.

Of course, I don't know how it happened, but the second scenario seemed more plausible to me. So in proceeding with the grommet holes, I decided to take a chance on it and try misaligning the front and back side a bit.


normal alignment vs futzed:

The pp2 vest is the one vest I know for sure had brass grommets. They are put on with the backside facing front. I'm using C.S. Osborne rolled rim #1 (13/32" hole) grommets again with a 7/16" or 11mm hole punch, the same as on my ESB build.

okay. Now let's take a chance on ruining this wonderful new vest.


point of no return.

Let's remember to keep in mind this is just a hobby. It doesn't have to be perfect. Just have fun. If you find yourself getting stressed about things like this its time to take a step back.

Okay, I did lose some sleep over this, but after a long session with the therapist I'm feeling better.

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There's a good chance I'm wrong about the cause of that backside drooping down, but doing it this way seems to result in a decent reproduction. After doing this, I'm leaning more towards the backside being cut too long or some other possibility.

Also note, I pointed out to clothears it would be nice if they did a bad dye job on the vest to replicate the blue splotches all over the real one. They couldn't offer that, but they did come up with a brilliant solution to simulate it. I think it worked. Notice the blue splotches. Subtle and well done.

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Still need to fine tune the placement of the armor. Not quite right yet.

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Starting to come together. Finally time to start painting.

Below is the exact same model airbrush from the same time period Mario used on the PP2 costume, a 70's Paasche VL. I had considered asking him if I could borrow his to paint my armor ( ! ) but when I asked if he still uses it, he said his wife uses it for decorating cakes now. So I declined to press further. Instead I got this one with a serial number not too off from his, before they changed to a different design with interchangeable brush head sizes.

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I guess if YOU'RE satisfied with an exact match that's only CLOSE to the serial number of the original, we'll have to let your accuracy slide! Seriously though, your attention to detail and passion for not just replicating the look but also the process and tools used is impressive. I lack the patience for that (as is probably clear by my little Fett factory in the basement :) ).
we'll have to let your accuracy slide!
Ha. Actually I've been wanting to upgrade to a double action brush for a long time, so this was the perfect excuse. The way I used my single action was pretty much like a double action anyway, with my free hand adjusting the nozzle on the fly as I sprayed. Pretty ridiculous. But I wish I could go as fast as you because I'd rather be looking at the finished costume in my office rather than the to-do list every weekend.
dental mirror installed on the ab plate. This is essentially how they put them on, although undoubtedly there were variations between the suits.


I spent a lot of time looking at every pic of the dental mirror on PP2 and to me it looks like it was painted over. Now, of course, the PP2 ab in the marketing photos was the PP1 ab painted by Joe Johnston (eventually repainted to become the ROTJ SE ab) so it would mean Joe didn't bother to mask it. So apparently he changed his mind by the time he got to the hero costume.

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In every photo it looks like this... where the mirror looks the same as the Floquil silver. So I painted over it. You can also see how its not sitting up against the holes too close either. Looks like some green in there, too

So I painted over mine.
Loving this build! Catching up on the flight suit and vest info. I need to re-hem my PP2 vest so that the ab plate is at the very bottom. I go with a discount vest from KrytptonTop because at the volume I do Fett'ing I can't A) wait for the Arkady or Clothears backlog and B) need to keep spend reasonable. I've gotten better at futzing the vest to make it appear more accurate. Love the knee colors. I got mine close to the eye with a multi-day misting party :)
Final job on the lineage knees. Far from perfect. I messed up and had to do misting to save myself yet again. I didn't want to toss all that Floquil paint away, so because of that, I lost some of the ability to do the cool scuffs and light sanding they did in various places on the knees. It wouldn't look the same with the extra color layers that got laid in to correct the first pass.