3PO build

[Conqueror_Worm]

Hmm...those look like they would be good for the upper torso connection. 
I used something similar in the knees. I pressed T-nuts into the outside of the thigh piece, and used set screws to connect the thigh and shin. Short, unthreaded, aluminum tubes are in the shin, to receive the set screws. The T-nuts are between the thigh and shin, so even if they come loose, they won't fall out. Fingers crossed that the set screws won't back out while i'm wearing it.
It has definitely been a challenge to connect the parts. Most material is only 1/8" thick. The fasteners on the inside of the costume should be flush, so I don't get stabbed, and I can't have visible fasteners on the outside, cause that wouldn't be accurate. Ideally, the fasteners could also be removed by hand (I have nightmares about loosing a hex wrench while i'm in costume).





I've been experimenting with using rare earth magnets to hold the head together.  It seems to be a strong connection, and the head can quickly removed.  I still need to test it while I'm wearing the neck piece.