scottrooper

I made my shin guards out of foam and covered with black vinyl. Same with my gauntlets. My boots are just are chelsea style but I got a cheap pair and painted the sole grey.

I think the cosplaysky tunic and pants match the crl, but in terms of fit and sizing you might need to get it tailored to fit you.

I used Chelsea type boots with the gators (shins) over the top. Have a look at the CRL for this costume.
 
Kallus CRL
 
Hope this helps.

Making them seamless was probably the hardest part of my Kallus build and I want to re-do my leg guards eventually. I used a kit made by Dave Sack and modified with leg guards with ABS sheets. I filled the cracks with ABS paste and some plastic weld after a few failed attempts with other materials. It seems to be holding up so far and for photos looks good. The only tricky thing is having to slide them on before I can put my boots on but since Kallus doesn't need really tall boots I haven't had too much trouble. I think the EVA and vinyl idea would work well too, I debated doing something like that myself.
 
For the gloves a seam is fine, like @scottrooper said. I used thin EVA foam and used leather that matched the gloves I had. I used contact cement to glue the foam together. I then cut the leather in the same shape as the foam but with about 5/8 in seam allowance, sewed up the edge to make a tube and then pulled it over the foam before glueing down the edges. I have some progress shots in my build thread here:
Feel free to message me if you have any questions!
 
 

Hi Joe,
 
My gauntlets have a seam at the side which matches with the on screen ones and also I have a seam down the back of the shins. The basic level of the crl allows for a seam as I found it impossible do it this otherwise.
 
Cheers

Scott
ID-3373

Always happy to see another Kallus. Niels from the Netherlands has made is own suit so you could have a look at his build threads.

Always happy to see another Kallus. Niels from the Netherlands has made is own suit so you could have a look at his build threads.

Great job Ricky. Its great to see Kallus getting more love. 

There is one called Heart of an Empire about how the 501st was created. Well worth watching.
 
http://starwarsfans.wikia.com/wiki/Heart_of_an_Empire
 
Cheers

Scott
CC-3373