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ROTJ Scratch Build WIP - Advice Welcome

  1. #1
    mcfarlj3's Avatar
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    ROTJ Scratch Build WIP - Advice Welcome

    Greetings everyone! I've been working on my first Boba Fett for about two months now. This forum has been an incredible tool for my build so I decided to post my progress and hopefully give and get advice.

    For now my deadline is Halloween, but my end goal is to join the 501st, not to mention have a great Boba Fett to display.

    I started with the armor to get a little experience working with the materials before attempting the helmet and more complex pieces. I used the WOF templates.
    img_0001-jpg

    Here are the pieces cut out of 3mm sintra. A local sign store was kind enough to give me scrap sintra for free.
    img_0002-jpg

    I shaped the sintra using a heat gun. Here are a few amor pieces on a duct tape mannequin I made.
    img_0003-jpg

    img_0009-jpg

    img_0010-jpg

    img_0011-jpg

    img_0012-jpg
    Last edited by mcfarlj3; 3 Weeks Ago at 7:41 PM.

  2. #2
    mcfarlj3's Avatar
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    Jun 2014
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Here are a few pictures of the knees. I used the WOF templates. I still need to work on the knee darts, but here's what I have so far.
    img_0004-jpg

    Before and after some sanding.
    img_0005-jpg

    img_0006-jpgimg_0007-jpgimg_0008-jpg

    - - - Updated - - -

    Again, I used the WOF templates for the side pouches.
    img_0014-jpgimg_0015-jpg

  3. #3
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Im using an old pair of coveralls as my flight suit until I can get my hands on a screen accurate/501st approved suit.
    img_0013-jpg

    After many rounds of bleach I was able to achieve a decent color.
    img_0046-jpg

  4. #4
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I also decided to scratch build the girth belt out of clothes line and yarn (for the weaving). Although the results aren't too bad, I'll probably just end up buying a real girth belt in the long run.
    img_0039-jpg

    I initially dyed the belt with tea and I'll eventually paint/dye it red.
    img_0043-jpg
    Last edited by mcfarlj3; 3 Weeks Ago at 9:42 PM.

  5. #5
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I used the tutorial on here to make my flak vest. It seems like a good fit. What are your thoughts?
    img_0044-jpgimg_0045-jpgimg_0050-jpg

    - - - Updated - - -

    And here are a few pictures of the neck seal.
    img_0040-jpgimg_0042-jpg
    Last edited by mcfarlj3; 1 Week Ago at 1:06 PM.

  6. #6
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Even before I started the flak vest I was a little concerned that the armor was too big. I'm 5'6 and used the corresponding WOF templates. Another scratch builder of the same height used the Raf templates at 90% and it looks really good. I'm considering do the same. Thoughts?
    img_0051-jpg

  7. #7
    lukefett's Avatar
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    Aug 2014
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I would make the armor smaller- Looks great but its a little to big...
    Everything else looks great- love your jumpsuit..

  8. #8
    animattor's Avatar
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    Feb 2014
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    Las Vegas NV
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Looks good, the back armor looks to have crimped at the shoulder curve. My scratch built with a heat gun did the same, so I redid it using the perperkura method using card stock then used architecture board and then smooth cast to build it up. It was a much better build.

  9. #9
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Thanks for the tips on the back plate. I've been meaning to rework it, but at the time I was just unhappy with it so I decided to take a break and work on the soft parts.

  10. #10
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Question: I've been looking at reference pictures of the cape in the gallery trying to figure out where to put the grommet for attaching it to the shoulder. In some pictures it's in the corner, but in others it's like 6-8 inches in from the corner. Does this mean it's personal preference or is one better than the other?

  11. #11
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I finished sewing the cape, but still unsure where I'll put the grommet. Then I'll start on weathering, etc.
    img_0056-jpg

    Here's the girth belt that I finished up today too. I ended up spray painting because I didn't want to deal with dye. Instead of the metal buckles I used 1 inch plastic buckles. I thought the elastic I had was the same, but it ended up being 1 1/2 inch. Oh well. It's only a temporary girth belt for now and will serve the purpose.
    img_0058-jpg img_0059-jpg

    I'm going to work on resizing the chest armor next.

  12. #12
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Yesterday I worked on resizing the armor and cutting out a few more pieces for the knees and other parts. I'll post a few pictures later after I get some more supplies to continue working on those parts. I also started working on the ammo belt using Batninja's tutorial. Here's one of the wooden blocks and the template I made. So I'll use the template to cut out a piece of vinyl to wrap around the block, but I'm wondering what's the best glue to use? The tutorial uses hot glue but will that be strong/good enough? I've never tried gluing fabric to wood before.
    image-jpg

  13. #13
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Had time today to work on the knee darts. Went to Lowe's and picked up a few nylon spacers. The final dart is a little short but I'm happy with the result. Still working on installing them on the knee armor. Updates on that shortly.
    image-jpgimage-jpg

    I've also been working on resizing my armor. It's looking much better. I'm getting excited about painting, but my thought is that it would be better to attach the armor to the vest before painting. I'll be using the bolt method. Thoughts?

  14. #14
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Another "in progress" shot of the knee darts. I layered 3mm Sintra to build up the knee dart box. The final layer has two 3/4 in holes cut out for the knee darts to fit into. Tons of sanding ahead to say the least. I'm not sure what to use for the cone shaped dart on the right knee. Any suggestions?
    image-jpgimage-jpg

  15. #15
    Micheltenc's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Hi. Great progress so far. On the dart: center pin of an old record player or the Cutoff and viled part of crossscrewdriver?

  16. #16

    Member Since
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    This is looking great. Keep up the good work!

  17. #17
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Basically finished the ammo belt this morning. Still deciding how to attach it. Velcro? Or would you suggest something else?
    img_0017-jpgimg_0019-jpg
    Last edited by mcfarlj3; 1 Week Ago at 1:05 PM.

  18. #18

    Member Since
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    Calgary,Alberta, Canada
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Dude! Everything looks great so far, keep it up!

  19. #19
    Jesuit24's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Velcro would be a safe bet. Two strips horizontal and parallel along the top and bottom edge.

  20. #20
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I finally got done resizing the armor and today I worked on attaching the armor to the flak vest. I used the nuts and bolts method. First, I traced the end of the bolt on the armor piece and extended the lines so I could center the bolt when gluing.
    img_0020-jpg

    Then I put a dab of nail polish at the center of each mark and while wearing the flak vest I pushed the armor piece onto the vest. The dots of nail polish were then cut out and grommets were installed.
    img_0022-jpg

    Next I glued the bolts onto the armor. I'm going to use Bondo as well to secure the bolts even further.
    img_0023-jpg

    Here's what I've got so far. The armor looks bigger in the pictures than it looks in the mirror, so hopefully when everything is put together it will be ok. The left chest piece is a little off, but I feel ok about the results. If anyone has any tips to fine tune armor after grommets and bolts are placed feel free to share.
    img_0024-jpgimg_0025-jpg

  21. #21
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I can't decide how to attach the shoulder bells. I'm planning on using grommets, but don't want to place the grommet over the stitching on the ribs of the sleeve. Should I put the grommet in first to avoid the ribbing, then place the shoulder bell on the sleeve and make a mark on the shoulder bell through the grommet?

  22. #22
    SPY007's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Very nice work. If you are scratch building a helmet, I recommended Rafel Fett's templates. They are more accurate than WOF's Girth belts aren't that expensive, look for morhair. You can buy cheap hair extensions at Sally Beauty supply for Wookie braids.

  23. #23
    mcfarlj3's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    Thanks Spy007. After painting my armor, the helmet is next. I've been mentally prepping for the helmet and planned on using Rafel Fett's templates. A friend of mine has horses so we'll see if I can get some horse hair for the Wookie braids. Also, after placing the bolts I'm beginning to wonder if you could cut off the head of the bolt and glue/bondo the bolt threads to the armor and then be able to pull the armor as close as possible to the vest. The bolt head wouldn't get in the way and leave a gap. But that's a project for the future. I guess a Fett is never really "finished".

  24. #24
    animattor's Avatar
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    This build is looking very solid man. Your knees look very good keep it up!

  25. #25
    mcfarlj3's Avatar
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    Omaha, NE
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    Re: ROTJ Scratch Build WIP - Advice Welcome

    I plan on using rattlecans for my paint job. Are Valspar and Krylon really as bad as people say? I know Rustoleum is good, but it's also more expensive.
    Last edited by mcfarlj3; 4 Days Ago at 2:51 PM.

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