X-Wing Pilot Uniform — Chest Box
Source: Star Wars A New Hope
To create this chestbox I purchased an 8" x 2" board and cut a 9 1/2" long piece. I then set my table saw to a 30° angle and cut the bottom. For the top I set my band saw to the same angle. I had to flip the blade on the bandsaw to cut one side out. Once it is cut out sand it smooth and the fill any hole with wood putty.
The cut the groves in the chestbox just below the toggle buttons, I set my table saw blade low so it wouldn't cut the box very deep. I then placed a board in the way to act as a stop so I would only cut the groves a specific length.
For the hole to connect the hose, I used a drill bit used for cutting holes in doors for a door knob kit. The drill bit comes with two sizes. One is the size for the door knob, the other is for the door latch. Use the one for the door latch (shown above).
Be sure the box is sanded smooth and then prime. Sand the primer once it is dried to make sure you have a really smooth surface.
Spray paint the box a dull gray and let it dry.
Use painters tape to mask off the black area. I used the picture at the top as a guide to how I masked it off.
Use wood glue inside the chestbox to glue the hose on.
I purchased 1" olive drab straps at my Army Navy store and used screws and washers to attach it to the back of the chestbox. For the waist strap, I bought a heavy-duty snap kit and added a snap to one end of the strap so it would snap to the chestbox for an easy on and off.
For toggle buttons I just carved a scrap piece of wood into a V-shape and rounded the edges. Prime and then paint two white and one a gray(be sure it is a different gray from the chestbox).
For the airhose. I used a dishwasher drain hose found at Lowe's and Home Depot for about $8.
For the indicators, I called a plexiglass shop and asked for 1" x 1" squares in red, blue and clear (they didn't have white). Take the clear ones and paint one side white.
Source: Dewback Wing
A concern with many creators is how to attach the hose without cutting a hole in the flight suit. One suggestion is to use earth magnets and washers on each side of the flight suit.
Although I didn't put them on this chestbox, Elvis Trooper makes great hardware for X-Wing chestboxes.
For the outlining around the indicators, I bought a sheet of adhesive backed Avery paper and cut it into 1/8" strips. Use the image at the top as a guide to the placement of the white outlining.
