1. Member Since
    Apr 2015
    6 Hours Ago - May 24, 2015, 9:42 PM - Merkava74's mannequin build #1

    So I decided to build my own mannequin for my Boba Fett costume, since the flight suit is going to be made to measure, and standard mannequins just won't cut it. The mannequin is going to have a PVC skeleton, covered by cling-wrap and duct tape, and filled with bean-bag foam pellets to keep the weight down. I have tried expanding foam, with disastrous results as the foam failed to dry I think because I sprayed too much too fast. Also, it did not fill out the carcass as nicely as I had wanted it to. Hence I went for the bean bag pellets route, which gave me more control.

    Here is the skeleton template made out of PVC pipes and T-connectors. Simple straight connections except for the arms, which will be bent using heat gun:

  2. Member Since
    Apr 2015
    6 Hours Ago - May 24, 2015, 10:01 PM - Re: Merkava74's mannequin build #2

    So the rules of duct-taping yourself are pretty simple:

    1. Find someone YOU CAN TRUST COMPLETELY (In this case my wife);

    2. Recall, before you begin, if you have any unresolved quarrels with her that might result in you being held ransom for new dresses or bags;

    3. Do not, in any circumstance, start a new quarrel once the first duct tape goes on.

    If the above 3 are fulfilled, you may begin:

    1. Cling wrap your entire body, making sure no skin is exposed. Other forumners have used alternatives such as skin suits or old clothing. I prefer cling wrap as it best represents the actual contours of your body. Having said that, do bear in mind to do it fast, as your entire skin will not be able to breathe during this period. I would suggest doing this in an air-conditioned room so you don't perspire, and everyone is in a good and pleasant frame of mind.

  3. Member Since
    Apr 2015
    6 Hours Ago - May 24, 2015, 10:15 PM - Re: Merkava74's mannequin build #3

    2. Next, the duct tape goes on. I found out that cutting strips is much neater than going round and round your body, as the latter will produce more creases. If you are suffering from OCD, then making sure you have sufficient tape of the same colour is paramount. If not, go crazy with the colours!

    Here is the completed wrap. Note that blood circulation through your body at this stage is restricted. I have made a simple PVC blaster so that my hands can be taped in this posture. For modesty, I have photoshopped a helmet onto my face.

  4. Member Since
    Nov 2014
    6 Hours Ago - May 24, 2015, 10:19 PM - Re: Merkava74's mannequin build #4

    Sweet. Duct tape mannequin build. I will watch with great interest..
  5. Member Since
    Apr 2015
    6 Hours Ago - May 24, 2015, 10:25 PM - Re: Merkava74's mannequin build #5

    3. Next up, time to cut the wrap out. Do use a rounded point pair of scissors so that it doesn't cut into your skin. Remember that the cling-wrap and duct-tape are tight around skin, and you have very little manoeuvre space. This is the cut lines that I (my wife) made on the back:

    And here's the cut-out carcass:

  6. Member Since
    Apr 2015
    6 Hours Ago - May 24, 2015, 10:33 PM - Re: Merkava74's mannequin build #6

    4. The next step is to tape up the cut lines so that your carcass is whole again. I taped it up to the middle of the back so that I will have enough space to pour in my bean-bag pellets. The carcass is position over the PVC skeleton, and the ankles taped shut. Note that at this stage, I made a much sturdier base for the mannequin. This will be removed later. The bean-bag pellets are really easy to deal with. Pout them in, push them down, and pack them tight so that they fill up the shape of the carcass. Do this slowly, level by level so that each section gets as much pellets as it can. I also reinforced some areas with sponge. That is optional.

    You can see that I have cut the arms out. This is CRUCIAL as with the arms attached, there is NO WAY to wear the flight suit. REMEMBER THIS STEP!

  7. Member Since
    Apr 2015
    5 Hours Ago - May 24, 2015, 10:41 PM - Re: Merkava74's mannequin build #7

    This is what it looks like on the inside. I measure the lengths of the PVC pipes as I go along so that I can finally get the shoulder joints exactly where the arm holes are:

    And the completely filled mannequin. I reinforced the shoulders with sponge. The arms will come later. It looks a little disproportionate, probably due to the angle of the photo:

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