DIY jetpack harness (somewhat budget)

Hello all!

I am relatively new to the board but I have been using as a resource for amassing my ESB fett and it has been awesome! I have decided to give back (hopefully with something some will find useful) by documenting a jet pack harness that I am creating. I wanted something that did a good job at weight distribution with realistic straps, sturdy d-rings, but not cost too much.

While searching for various scuba harnesses, I came across the Dive Rite basic harness. SCUBA Diving Equipment for Technical, Sidemount, Rebreather, Wreck and Cave Diving: Dive Rite, Inc - Product Catalog - Basic Harness

The buckle can pass for me but could easily be replaced with a US divers. I ended up getting the harness on ebay for around $30. You can see what came in the photo.

So this really can not be used without some kind of backplate. The one shown on the website is usually around $60-70 so I decided to make my own. I found the measurements of the backplate online which are:

39.4 cm tall (15.5 in)
26.7 cm wide at base (10.5 in)
22.9 cm wide at top (9 in)

I measured this out on cardboard and cut it out to use as a template. I kept a center line on the template to use for other measurements later on.


The next step was to mark out the holes for the strap to pass through. They needed to be about 2 in to accommodate the strap. I kind of just guessed on their location based on the picture of the backplate and just made sure it was symmetrical between sides. I then cut out the slots using an x-acto knife and then also rounded the corners.



I then fed the strap through to get an idea of what it would look like. There is a grommet at the midpoint in the strap which you line up in the center of the backplate to know you have an even amount of strap on each side.


So this is where I am at right now. I plan to have two of the d-rings on the front of the shoulder straps which I will attach my jetpack straps to through the backplate.

Does anyone have any ideas on a good material to make the backplate? I am looking for something durable and easy to work with/cut but still have some bend to it so I can form it to my back.

Excellent idea and an awesome build so far! Just keep us posted as you progress on this.

For the back plate you might use a thicker piece of Sintra. If you use a PVC (and related) bucket or barrel, and cut your template in upright position, the existing curvature will help you to fit easily that piece on your back.

Wow. this is great! I can use this for my (non-Fett) Mandalorian build. Thanks!

Good idea on the bucket or barrel. That is what I was thinking of trying to use was something with a natural curve. No real updates as of yet. I am thinking about streamlining the backplate by cutting some curves into each side so it is almost more like a horizontal H shape. Not sure if I will though, need to try to get some material first to check the fit.

Alright, so I finally had some free time to finish the harness. I was really bad about taking any progress photos but I have a bunch of the finished product.

Ended up using a 12X18 sheet of 2mm aluminum ($10) to make the backplate. I traced the initial cardboard template to the aluminum and cut it using heavy duty tin snips. To cut the slots that the strap passes through, I used a high speed rotary tool with a metal cutting wheel.

I did not quite like the fit of the plate initially so I added a couple bends down the back to make a better contour. It still seemed too bulky so I cut out a section from each side and it fit much better. The d-rings are lined up right in front of my shoulders for attachment of the straps to the jet pack.

Overall cost ended up being just under $50 (depending on what tools you already have available) and it turned out better than expected! Feels pretty high quality for the cost.

Any suggestions on what to make the jet pack attachment straps out of?