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  1. Member Since
    Mar 2017
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    17
    Mar 30, 2017, 3:47 PM - Kid's Boba Fett Costume build WIP #1

    So my son wants to be Boba Fett for Halloween this year and we’re getting an early start on the costume. He's been Han Solo and a FO stormtrooper before with some props I made but this will really stretch my model making abilities and I've found this forum is great for references and tips. I don't want to break the bank on making the costume so I'm working with stuff I've got around my shop for parts since he'll outgrow the costume in one year. Who knows, if it goes well I may decode to build one for myself on a bigger budget.

    We started with the blaster last week. For references I'm using a review of Master Replicas Boba Fett Blaster screen replica review for pictures and some overall dimensions, and WOFs Weebly blueprints as patterns

    I scaled the prints up to full size and cut a dummy profile of a Weebly out to see how it fit on me. Then I scaled it down for his 4’5” frame and cut out a dummy profile from some scrap plywood to see how it fit him. Once I was satisfied and he was happy with the fit I printed out the patterns. I ended up scaling it down from full size to about 75%

    Here’s the start of the blaster. The handle is ½” plywood. The buttstock extension is a pice of ½” plywood resawed down to a little over 3/8”. The buttstock is two pieces of ¾” MDF glued together. The barrel is a piece of 1.25” sch40 PVC.
    Click image for larger version. 

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    I cut the extension and the handgrip on the scroll saw. The buttstock was cut to rough shape on the bandsaw. I used a router with a pattern bit to cut the recess for the stock extension. Then I used a microplane rasp and power carver to shape the stock.



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    More to come as I get some pics sorted out and uploaded.
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  3. Skyfire's Avatar
    Member Since
    Dec 2014
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    266
    Mar 31, 2017, 1:40 AM - Re: Kid's Boba Fett Costume build WIP #2

    I like what your doing with that blaster! Are you going for for more of a ESB, ROTJ or a mishmash of the two?
  4. Member Since
    Mar 2017
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    Mar 31, 2017, 8:50 AM - Re: Kid's Boba Fett Costume build WIP #3

    Quote Skyfire said: View Post
    I like what your doing with that blaster! Are you going for for more of a ESB, ROTJ or a mishmash of the two?
    Going for the ROTJ look. He likes the cooling fins on the barrel and the more futuristic blaster looking tip on that version. The tip will be easy. I'm going to turn that on my father lathe out of wood. I'm scratching my head as to how to do the raised segments under the fins. Not so much the fin itself,I'll cut some thin strip from maple and glue them on. It's the underlying fin sections I'm puzzled about. How to get the raised, segmented look. I'm leaning towards using those thin flexible cutting boards sliced into strips and then glued to the barrel. They're thin enough they can be heated and formed to shape easily over the barrel and glued on. Then the actual fins go on top of that.

    My other option is to score the surface of the barrel using a straightedge and a utility knife.
  5. Skyfire's Avatar
    Member Since
    Dec 2014
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    266
    Mar 31, 2017, 10:51 AM - Re: Kid's Boba Fett Costume build WIP #4

    Windshield wiper blades are similar to t-tracks. For a long time they were thought to have used them on blaster shrouds and lightsaber grips until more info was found out.
  6. Member Since
    Mar 2017
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    17
    Mar 31, 2017, 12:43 PM - Re: Kid's Boba Fett Costume build WIP #5

    That's what I had heard too. I thought about going that route. I need to change the blades on the vehicles anyway. lol. I may mock it up with some carpet tape and see how it looks.
  7. Member Since
    Mar 2017
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    Mar 31, 2017, 1:00 PM - Re: Kid's Boba Fett Costume build WIP #6

    Next up the barrel. I used a Vblock and drew a straight line down about two inches of the barrel and drilled out about two inches along the line with a forstner bit. then I clamped it in the vise and filed it to fit the handgrip blank.
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    Once that was done I put the barrel on the grip blank and drilled two countersunk holes for some #6x1.5" screws to hold the barrel to the grip blank. To give it s a bit more support Icut two pieces of3/4" MDF to fit in the empty space at the rear of the barrel/grip assembly and glued those in place.

    Click image for larger version. 

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    With that dry fit complete I traced the OD of a scrap piece of 1.25" PVC pipe and cut two support blocks and shaped them similar to the curvature at the rear of the Weebly where the cylinder is.

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    There's the completed interior/exterior supports with and without the barrel.
  8. Member Since
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    Apr 4, 2017, 6:50 AM - Re: Kid's Boba Fett Costume build WIP #7

    For the cylinder I took a piece of thin wall 4" PVC, cut it in half and used a heat gun to shape it around the barrel to simulate the cylinder on the blaster. Once I had it shaped to my liking I drilled two small holes through the PVC into the wooden blocks. I spread epoxy on the barrel where the piece would lay, used a 18 gauge brad nailer and nailed the piece in place through the holes I drilled(if you don't drill holes in PVC before using a nail gun the PVC will crack) I clamped it in place and let the epoxy set.

    Once that was done I used my power carver to shape the cylinder as shown in the picture.
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    I then cut two pieces out of some flattened thin wall PVC to mimic the hinge on the weebly cylinder and glued them into place on the blaster.
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    Now to apply some JB weld wood putty and shape the bottom portion to the cylinder.
  9. Snappy's Avatar
    Member Since
    Jan 2017
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    45
    Apr 4, 2017, 9:28 PM - Re: Kid's Boba Fett Costume build WIP #8

    Always interesting to see scratch builds come to life. Those of us obsessed with the movies want everything as screen accurate as possible, but we're all putting on costumes pretending to be plastic space men. Kids get it, you get close and their imaginations take flight. I wonder what my daughter will be into.
  10. Member Since
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    4 Weeks Ago - Apr 18, 2017, 8:31 PM - Re: Kid's Boba Fett Costume build WIP #9

    Yeah. He keeps saying, "Let's go for screen accurate." I tell him "we'll get close buddy. trust me, this will be the coolest costume at your school next school year." I'll have to see if I can find the pic of him as Han Solo or at least the blaster I made for him.

    Maybe she'll ask to be a sparkly Boba Fett ballerina. LOL ever seen the Darth Vader ballerina outfit a guy made for his daughter?

    I've got some more pics coming soon and then I'll be ready to work on the ribbing on the barrel.

    Quote Snappy said: View Post
    Always interesting to see scratch builds come to life. Those of us obsessed with the movies want everything as screen accurate as possible, but we're all putting on costumes pretending to be plastic space men. Kids get it, you get close and their imaginations take flight. I wonder what my daughter will be into.
  11. Member Since
    Mar 2017
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    17
    1 Week Ago - May 10, 2017, 3:01 PM - Re: Kid's Boba Fett Costume build WIP #10

    Been slacking with posts so here's what I've been up to with my low/no budget kid's sized blaster. Next up is the barrel portion behind the cooling fins.

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    I started with a PVC coupler for 1.25" pipe. So it would slide on easily I used a round rasp in my drill press to enlarge it just a bit.

    Click image for larger version. 

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    With that complete I needed to make the two rings on either end of the barrel section. For that I used a 2" dia piece of PVC cut down to 4" in length for ease of cuttingin the table saw later. (note what's in the pic was a spare piece I had for purposes of taking the pic)

    I cut an MDF plug to insert in the PVC so I could find the center and keep the drill bit on track and then drilled out the tube so it would slip over the coupler.Click image for larger version. 

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    Once that was drilled out I cut the rings to width on the table saw. Click image for larger version. 

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    Now I needed to drill out the recess in the front for the cooling fins to sit in so I repeated the same process above with the MDF plug and the drill press.Click image for larger version. 

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    Unfortunately I forgot to add the small fins on the side for this piece so I had to do that after the fact. Using a small v-block in drilled holes through both sides at once and used my power carver to smooth ou the slots as best I could and cut two small fins from some flattened PVC and epoxied them in place.Click image for larger version. 

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    And here's the whole assembly on the blaster.Click image for larger version. 

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  12. Member Since
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    1 Week Ago - May 10, 2017, 3:11 PM - Re: Kid's Boba Fett Costume build WIP #11

    Now for the pairs of fins on the cylinder at the rear. I cut some more flattened PVC to shape and glued to together. Once they dried I epoxied them in place on the blaster.
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  13. Member Since
    May 2016
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    26
    1 Week Ago - May 10, 2017, 4:56 PM - Re: Kid's Boba Fett Costume build WIP #12

    This is a really special thing you're doing for your son. He should feel proud to have a dad like you. Blaster is looking great so far! I'll be watching this thread
  14. ShortFuse's Avatar
    Member Since
    Dec 2015
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    159
    1 Week Ago - May 10, 2017, 4:57 PM - Re: Kid's Boba Fett Costume build WIP #13

    Awesome job!
  15. Member Since
    Mar 2017
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    1 Week Ago - May 12, 2017, 8:28 AM - Re: Kid's Boba Fett Costume build WIP #14

    Thanks guys. He's pretty excited. He's excited to go to my dad's house to help me turn the cone for the tapered end of the barrel. Part of the deal was he needs to help me with the build. He's been doing a few things here and there with the blaster with some of the shaping and cutting of the handle and stock. He'll really get to help a lot with the jetpack which is next.

    Next up is the scope and cooling fins.

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