1. Member Since
    Jan 2014
    Apr 6, 2014, 11:10 AM - Budget Scratch Build ESB Boba WIP Thread #1

    Hi and first off thanks to everyone who has contributed to this site and particularly those who have give me insight on my other threads. This build, albeit early yet, has been a great adventure in learning about my favorite SW bounty hunter character of all time, Boba Fett. I've found the scratch build taxing on my nerves at times, not very "budget" after purchasing heavy paper, chipboard, Heat gun, bondo, resin, protective gloves, repirator, and some other items. I'm confident to harden this helmet I made though and paint it up thanks to all the great information on this site. I look forward and will take great pride in building this costume from scratch and have high hopes it looks close to a costume that would look authentic. I don't really have dreams to troop or join the 501 or Mercs. My goal is to have a really kick *** costume for Halloween, take my kids trick or treating in, or go to parties for Halloween in.

    So the helmet I initially built from Pepakura and didn't like it enough to move forward. It seemed a little big for my head and bumped my shoulders when I moved my head. I still have it and maybe will do something with it someday who know's?
    Click image for larger version. 

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    Toolguy301 pointed me towards Skip's Pepakura helmet and I build that one quick and dirty out of regular paper and scotch tape and found it fit me better. So I went ahead and printed it out in 110 lb paper, built it up and reinforced most of it with chipboard. Also build the vents in the back of the helmet with sintra and installed. I'm planning to Rhondo the inside of the helmet and use smooth case 320 on the outside to harden it up!

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    I forgot to take a pic of the ears, but they are done and look great, ready for hardening. There is no stalk and top part in Skips Pep file, but I have those pieces from my first helmet build and plan on using them if I'm able to harden them ok. If anyone has tips on installing the ear pieces and making them functional I'd appreciate that advice or pointing me to a link. (Insert comment about how to use search function here) hehe.

    So question i have now is should i resin the inside of the helmet before I Rhondo slush it?

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    Who said you can't build armor for free? I went to some local Sign Shops and told them I was working on an art project (Which I feel this is) and was surprised at how much sintra scraps they just gave me. You'll notice the back of my armor is a grey color opposed to white like the rest. I needed a bigger piece and the last shop I went to told them size I needed and they went to the back, and brought out that grey piece and charged me $5 for it. It was just under the size I needed to build the back based on WOF's templates so if you look close against the template I had to cheat a bit on the sides and they are not as big as they should be, but for free (or close to free) and a budget build I can't complain.

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    I'm having issues with molding the Sintra. I'm using a heat gun and trying to bevel the edges, but it looks like ****. Going to build a beveled edges mold out of wood and use that to heat and bevel the edges with next... think it should work. .. fingers crossed.
    Last edited by Bsoder52; Apr 6, 2014 at 11:22 AM.
  2. Member Since
    Jan 2014
    Apr 6, 2014, 11:20 AM - Re: Budget Scratch Build ESB Boba WIP Thread #2

    So my EE3 plan was to buy a cheap plastic gun of the bay and build it up with a couple PVC pipes and a dowel and some pen caps and what not for the make shift scope.
    I removed the grip and drew out a blue print for the part that would connect the gun handel to the stock. Click image for larger version. 

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    Then I filled the inside of the grip with liquid nails along with putting some old washers in there for some added weight. This was a mistake however and the liquid nails hardened only to a point (this now a couple week later even). I plan to remove the liquid nails putty and bondo it so it will become completely hard. Then ill have a hard surface to sand down flat and be able to afix the connecting piece well I'm going to make out of wood.
    Click image for larger version. 

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ID:	75796I apic anyway just cause I took one.
  3. Member Since
    Jan 2014
    Apr 18, 2014, 2:26 PM - Re: Budget Scratch Build ESB Boba WIP Thread #3

    update - my plastic gun broke in half when trying to mess with bondoing it. Going to have to go to plan B for the gun.

    Got the inside of my helmet 2 coats of Rhondo and it's pretty solid. Going to cost case 320 the outside when I get some warmer nights here in Wisco.

    In the meantime made up some pepakura gauntlets and like how they are looking!!!Click image for larger version. 

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    the left Gauntlet has the RotJ Flame Thrower, but I had planned for an ESB build. Now I'm torn between ESB, ROTJ and SE! ARG
  4. Member Since
    Dec 2013
    Apr 18, 2014, 6:49 PM - Re: Budget Scratch Build ESB Boba WIP Thread #4

    looks great so far
  5. Member Since
    Jan 2014
    May 3, 2014, 9:18 PM - Re: Budget Scratch Build ESB Boba WIP Thread #5

    So I was a little worried that 3 coats of Rhondo on the inside of my bucket might be a little much and I was right. It's hard as a rock, but when I put it on my head my nose now hits the shield area. arg.
    Anyone had this happen? Hoping I can router out the inside a bit and it will fit yet!

    Also wondering what do do next with the gauntlets. Should I resin them up inside and out and then add a locking device or should I install a locking device first and resin over?

    Appreciate the continued help everyone!

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