I'm Peter from Poland.
On the occasion of an event StarForce 2009 in Torun (Poland) I prepared the Swamp Trooper costume for my 6 years old son (photo - my avatar).
About six months ago I decided to make a Boba Fett costume for him. Parts of this costume (Gauntlets, Amor, Helmet, Jetpack, Blaster) are built of polystyrene, PVC (2-5mm) and aluminum (Gauntlet's rocket, knee darts, jetpack beacon). Of course, aluminium parts have been made on a lathe. I prepared the technical drawings with dimensions matched to the child . Work on this costume took me about 150 hours so far. I think I'm halfway through the project.
I would like to invite you to the forum of 501th Polish Garrison. There is a small "photostory" about my project. This is the page in Polish, but if you have questions I will try to answer.