My 4 1/2 year old son wanted to be Boba Fett for Halloween so I did some research on The Dented Helmet over the past few months and was able to pull off a full costume for him finishing just in time for trick or treating. It's not 100% accurate, but not bad for a first attempt and he was definitely excited with the way it turned out.
The helmet is totally scratch-built using Alan's helmet templates. Thanks Alan! I was able to print out the templates at 75% scale in order to fit my son. The only difference from Alan's turorial was that I used a toy army helmet that can be found on eBay and in some toy stores. The dome worked out great and much easier than trying to piece together pieces of the batting helmet example. The helmet may be a little big for him but he should be able to wear it a few more years.
Thanks to everyone that shares information on the site - it was invaluable for putting this costume together. Let me know what you guys think.