Maulevolent’s TLJ First Order TK Build

[Maulevolent]

With over 12+ 501st costumes it’s been a shame that I haven’t done any white armor, so I decided that 2024 will be the year to change that!

I’ve loved the look of the First Order TK since I first saw it on screen, and particularly love the look with the riot baton and shield.  So I’ve taken the plunge!

501st CRL:  https://databank.501st.com/databank/Costuming:TK_TLJ

After significant research and multiple build threads, I’m going with the Denuo Novo (DN) armor kit which leans more towards TLJ than TFA, along with the TLJ helmet from DN.  This meant a low cost or budget build thread, as I often aim for Level 2/3 requirements for my own OCD/standards even if I don’t seek that level with the detachments.  

My complete build list with selected and ordered components is outlined below:

Required Costume Components

• Helmet Denuo Novo The Last Jedi FO Helmet (Premiere) - I also have the Standard but the Premiere has accurate clips.
• Neck Seal Denuo Novo Stormtrooper Neck Seal - While in Rome…
• Armor Kit Denuo Novo FO Stormtrooper Standard Kit 
• Gaskets: TrooperStore
• Gloves:  Endor Finders 
• Undersuit:  TrooperStore
• Boots:  KeepTrooping (fka Imperial Boots)

Component Uogrades

• Back/Yoke:  Ukswrath’s FOTK Shoulder Bell Support Bracket
• Holster:  R2Dan’s V2 Metal Holster
• Abdomen Section:  Rogue Repros Zippered Closure (Pending)
• Harness:  Tony Jobe’s FOTK Harness from the DN FOTK Kit Building Group on Facebook
• Pouches:  TrooperBay
• Gaskets: Thorsson Associates Workshop (TandAWorkshop)  Slipcast Latex Gasket Set
• Spats Sanotized Creations Urethane Resin Cast

Optional Accessories

• Riot Baton:  Black Series
• Riot Shield:  850 Armor Works Kit
• Blaster:  SE-44C Pistol, will be 3D printed as my sidearm.
• Blaster Rifle:  F-11D, 3D printed with lights and removable stock from Christopher Dunham

Much more to come as orders start to arrive!   I don’t have a clear time table for completion yet but hoping TerrifiCon will be a reasonable target for debut.  

Stay tuned!

Edited July 5, 2025 by Maulevolent

[Feliz]

Dude! Looking forward to seeing you in Armor!!! 

 

So....can you dress as both the TLJ TK and Kylo in one day and give yourself orders?

[Maulevolent]

11 minutes ago, Feliz said:

Dude! Looking forward to seeing you in Armor!!! 

 

So....can you dress as both the TLJ TK and Kylo in one day and give yourself orders?

Hmmm, I hadn’t considered that…can we count it as two troops if I do?

[Buccaneerbrawler]

So the number to match is 12+… I can’t wait to see this completed and watch the build process 

[Alay]

I'm so excited! This is gonna be awesome!!!!!

[Maulevolent]

Pieces and parts are starting to come in!  

Earlier in the week I received the gloves from Endor Finders, Ukswrath’s shoulder bell brackets, and Tony Jobe’s harness kit.  

 

The Black Series Riot Baton also arrived:

 

I managed to get in touch with 850 Armor Works for one of their Riot Shield kits and that’s in process.  I also downloaded files for the SE-44C blaster from the FISD forums and started printing the pieces for that:

Then today, about 5 days after I ordered, the BBB from Denuo Novo showed up at the door along with the helmet and neck seal!

Still several things on order but I’ll start unboxing soon and should be able to start the trimming process!

[Maulevolent]

I've been reluctant to break into the armor boxes just yet as I need to finish a few other projects and setup my workshop for the build before I start trimming.  But in the interim, I'm continuing to accumulate various pieces and parts.  As I mentioned, I'm targeting Level 3/Centurion requirements for this build, so several things go well beyond the basic requirements.

My upgraded rubber gaskets arrived from TandAWorkshop.  These are slipcast latex gaskets and they arrived untrimmed and still coated in release agent.  This is the after photo after a couple of hours of trimming and cleanup:

I'm still going to go over them a couple more times with rubber cleaner/conditioner.  Also, my undersuit arrived from TrooperStore, which has the rubberized material for the shorts meeting level 3 requirements integrated.  I'm really happy with the fit and finish and also that it has a two-way zip for those future bio breaks.  I went up several sizes (XXL) based on their size charts and reviews that consistently mentioned the suits ran small.  I'm 5'11 and 210 with broad shoulders and while it's a little loose in the arms, lengthwise and overall the fit is great:

My upgraded pouches from TrooperBay also arrived (as the long pouch with the DN kit is undersized), as well as my functional metal holster from R2Dan:

 

Speaking of holsters, I'm working on printing the SE-44C pistol for the sidearm using The5thHorseman's files on the FISD forums.  I decided to print and finish two of them, one for my kit and the other will be donated for a daily raffle prize at Terrificon this year.  Still a few more pieces to print for the visor/sight then the joy of sanding and assembly will begin:

 

Finally, I did get a shipping notice from KeepTrooping that my boots are on the way, and I started printing a more accurate (and lighter) TLJ thermal detonator for the armor kit.  Hopefully more on both of those things in the next update as well as maybe unboxing at least the DN helmet.

 

 

[Maulevolent]

So I have a couple updates but hoping to start the actual build soon now that things are settling down.

I went ahead and printed a more accurate (and lighter!) TLJ thermal detonator to replace the resin one with the kit.  Still needs to be finished and painted:

 

I also printed accurate ridged rails for the TLJ forearms with a hole for the Allen key dome hex bolt:

 

Lastly, the raw pull for the riot shield came in from 850 Armor Works to add to the pile to be trimmed and finished:

 

More to come!

[Maulevolent]

I finally resumed this build several weeks ago, working through trimming and assembly.  I’m attempting to finish it before Weird Al but I’m not rushing it either.  I’m still working towards Level 3 requirements for no other reasons than my OCD and that I know I can.  Terrificon though will be my ultimate goal.

 

Trimming has been a combination of scissors, the Dremel, hand sanding with 120/320 grit, and emery boards to round the edges…

I also started working on filling the seams on the yoke using multiple thin layers of ABS slurry and a LOT of hand sanding.  While the effort was tedious, I’m very happy with the end result:

In between that, I also started working on finishing my TLJ accurate 3D printed thermal detonator to replace the resin TFA brick that came with the DN kit:

That’s a work in progress but progress nonetheless. I’ve also picked up a gorgeous F-11D blaster with lights and a magnetic removable stock to switch between blaster and rifle mode:

I snagged it from a maker in the First Order Stormtroopers FB group and it was worth every penny!

So a lot of momentum and progress, with more to come soon.

Edited June 12, 2025 by Maulevolent

[Gian Daro]

Wow. It's looking great! Can't wait to see it finished! 

[Maulevolent]

Continuing to make progress but I also decided to complicate things further and paint the armor for a richer white finish than the raw ABS.  I think the end result appearance will be worth it:

 

I also decided to upgrade the spats to a pair of flexible white urethane ones from Sanotized Creations.  Those are on order and en route:

 

[Maulevolent]

Progressing a bit more slowly this weekend but making progress nonetheless.  I started assembling the forearms after trimming to approximately the proper TLJ shape:

I also trimmed and assembled the abdominal plate and prepping it for ABS slurry fill on the side seams:

and priming the resin boxes to go with it:

 

My raw urethane resin spats also came in from Sanotized Creations.  I’ll work on these as I get further in the build:

Now to whip up a fresh batch of slurry for the seams and call it a night!

 

[Maulevolent]

So I hit a bit of a stall due to other commitments and some painting issues, but starting to pick up progress again.  I completed the assembly of the forearms with the accurate TLJ shape and 3D printed Picatinny rails.  These are primed and ready for paint along with the hand plates:

I also installed the metal shoulder support tabs on the yoke for the Level 3 requirement:

And I completed the paint and finish on the more accurate 3D printed thermal detonator, again to Level 3 standards. I’ll line the interior with neoprene once the paint cures and before mounting to the backplate:

Up next is finishing the seam fill on the abdominal section, primer, paint and assembly and then shifting focus to be lower body armor parts.  More to come.

 

Edited July 1, 2025 by Maulevolent

[Maulevolent]

I’m finally past a point where I feel closer to the finish than the start.  A lot of delays recently for various reasons, including refining the finishing and paint process for each piece, but I’m definitely building momentum!

First, I finished filling and smoothing the seams on the abdominal plate and primed the entire piece for painting.  This is the last of the significant modifications for approval/TLJ and glad to be done with slurry:

I also assembled and primed the ABS spats.  I will upgrade these to the urethane resin ones but the ABS were far enough along I could check them off:

 

Next, I did the Behr gloss white top coat on the forearms and hand plates:

And I also repainted the yoke after adding reinforcement to the shoulders and the metal tab for the shoulder bells:

With all that, I’ve got the difficult aspects of the upper body build mostly done, minus the details and strapping, and ready to start moving to the lower…

[Maulevolent]

More progress to close out the weekend.  I’ve had a lot of battles with dust and insects ruining great top coats, so I went ahead and setup a paint structure outside of my workshop:

 

and broke it in by finishing the top coats on the abdomen section.  Very happy with the seam work and finish on this piece:

I also finished trim and paint on the cod, posterior, knee plates:

Next up 🆙 is the final armor pieces I need to trim which are the thighs and shins.  Getting closer! 

 

[Backpacks Got Jets]

Lookin good so far!

[Swiftcloud]

Gonna be epic! Can’t wait to see the final result!

[Maulevolent]

I hit another pause as I was consumed by work and another project, but focusing the next few weeks on getting this done for Terrificon.  Today I spent part of the afternoon finishing the ab plate and belt boxes.  Really happy with the seams and overall finish here:

Also added the accurate hex screws to the 3D printed rails on the forearms:

This week I’m determined to finish trimming and assembling the thighs and shins. Stay tuned!

[Maulevolent]

Hit a major milestone this weekend as I’ve finished trimming the last of the armor parts, with the thighs and shins ready for assembly and paint:

 

I need to mark the holster and “Kit Kat” install points next with the printable templates then I can finish putting them together.  I also carved out the lower oval on the shins to back with the screen accurate fabric/gaffers tape.

All of the other pieces have been painted and are ready for final details and strapping:

I also revisited my resin printed SE-44C sidearm.  I ended up printing a new one piece shell and grip cover to go along with the other pieces and started to prime and paint.  The entire piece will be resin when I’m finished minus the pins and screws:

I have a full day at work on Monday before starting PTO until 8/11.  I should be on track to have at least the armor ready to debut at TerrifiCon!

 

Edited July 28, 2025 by Maulevolent

[Maulevolent]

Lot of progress today…finally a break in the heat and humidity allowed me to get the thighs and shins painted:

I also spent a lot of time on the fit and finish of the Ross parts. getting everything strapped and velxro’d:

I also rigged up the chest and back with magnets (no Velcro at all) for easy aligned on and off.  The 3D printed thermal detonator was also mounted and I aligned the tubing with black fabric to grip the detonator as well as black out the tube:

And the SE-44C enters its final stages of finish, pending the red LED and the holster mount:

Hoping to ride this momentum through the weekend and finish off the kit! Fingers crossed! 

[Maulevolent]

Continuing the momentum today.  Finished up the details on the now painted thighs and shins:

and also installed the fully functional holster and screws for the SE-44C:

I also started painting the resin belt boxes and trimmed up and started painting a pauldron:

 

Tomorrow will be finishing the belt and the remaining harness and strapping!

[Maulevolent]

Saturday progress…finished up the belt attaching all the resin boxes and upgrading the pouches with those from Trooperbay.

I also finished up the pauldron pending magnets to fix it to the armor.  It’s black for now but if I have time I’ll likely paint it red:

I also started working on the riot shield.  I trimmed the pulled shield and put down a few coats of primer on the shield and the resin pieces:

and I finished the last details on the SE-44C and have a matched set with the blaster rifle:

I had to order some 2” webbing to extend the a plate harness which should arrive tomorrow and I can resume on the strapping.  

[Maulevolent]

So unfortunately I’ve hit a snag during the final fitting.  The chest/yoke and ab plate need to be extended to fit on me properly and I don’t have the time or material to make the correction.  It looks great on the mannequin…

But less so on me…

I know what I need to do (e.g., extending the yoke at the shoulder and shimming the ab plate) it’s just going to be a bit before I can do it.  I’m really disappointed I won’t have this done for Terrificon especially after all the time spent the last several weeks, but I’m optimistic I’ll overcome this hurdle too in due time.