This is the Roughneck Joe armor, as modeled on the original Johnny Rico figure. Custom-made armor for the 12-inch 1996 Classic Collection GI Joe action figure. It is patterned from actual film-used armor. There are 47 individual pieces in each Roughneck Joe armor set. Materials used here are the same as in the actual props. EST-40 (A/B catalytic rubber, tinted gray) was used for all of the flexible pieces. Sil-Cast (A/B catalytic resin) was used for the accessories. This gives the armor a similar feel and assembly to that of the original.
Molded in three parts: Belly, Yoke and Back, then assembled in the same manner. In this case, Cyno'd together. All of the chevrons, side vents (we made "A-grade" armor for our Johnny figure) and webbing plates w/ rivets were molded accurately. The armor is finished with a chest rations pack and simulated water bottle pouch.
Detailes such as strap segments and buckles are put in place. 1/4-inch grosgrain ribbon was used to simulate the 2-inch nylon webbing. Tiny, molded buckles and adjusting rings were then fastened to the surface. To the left side, two fabric magazine pouches, with velcro flaps, made from black pack-cloth hold the two extra Morita clips. On the right side is attached the EST-40 thigh knife sheath, with elastic leg loops. This holds a removable knife within a fabric pocket. Under the armor, around the neck, is an EST-40 rubber georget with strap details.
The M-3 Tactical Helmet is made from Sil-Cast (A/B catalytic plastic, tinted gray). This simulated "A-grade" helmet has painted ear screens and a removable chin strap. However rarely worn since it obscures the figure's face. Foam inserts help keep Roughneck Joe in style!
The Morita Rifle, also made from Sil-Cast, has a removable clip (... the Original Roughneck Joe came with three, for those long fire-fights). Both the helmet and morita were sculpted from original film-used props. The Morita rifle has dual triggers, like the original. The pump action shotgun has a detailed grip, and the receiver has all the parts molded in there. The Morita came out a little thick, tucked under the figure's stiff elbow against the bulk of the costume, but we've had no complaints about his "bigger" gun.