The armor was made out of Plastic/Foam Place Mattes. Yes, the $1.00 each bargin bin place mattes. They need to be the old Grandma style ones. What you do is turn them over to the underside where there is texture. That is the side you paint. You simply have to paint it, then use silver and black paint to give it that worn metal look. I'm telling you, it sounds really stupid, but it's cheap and easy, and looks great. (Also light weight). They are cheap so you can pratice first. Then you have to Hot Glue them to the Blue Outfit. Now, What I did was made a Blue Jump suit, (or had my girl make it) and then made a seperate vest for all the armor, that velcroed in the back. That way, you can give it that layered look, and can make you self look slimer, or Bigger depending on your size. I had a gut, and I had to use and old belt on to "Suck it all in. "
Take a Picture of boba fett with you to the fabric store and match the colors the best you can. For the Wookie Hair, you use colored rope, that matches boba's.- Sew it too the vest, so it will stay on. You need a tatered old green cape as well. Agian, match it up. The Shoulder pads you can use place mattes as well. Same with his wrist armer. Now, all the gagets and flamerthower appperatus, I had to improvise. Take a trip to the junk yard or Hardware store and buy some stuff that looks the part.
Back Pack. What I did was buy PVC Pipe and made the main stuucture, and then used different size fittings for the rockets and the Missle. They never looked perfect, but it's an idea. Then I went to a Hobby supply store and got some platic sheets that I used to encase it all in. Some of it got melted from the glue I used, but made it look better. Again, you have to be pretty creative with the parts.