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.
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.
More to come as I get some pics sorted out and uploaded.