Stormcrow 85's WIP: Boba Fett - ESB

Well work is still crazy. Friday most people got the day off I went in at 7:30am and left work at 11:00pm. We are working towards a deadline that is kicking my butt. That being said I was able to get a tiny bit of work done, but more more so I purchased a 12" Boba Fett that was made by Hasbro in 2004. This website has wrecked me because while I really like this thing I am pointing out screen inaccuracies that before October I would have NEVER seen. The weather got up into the 60's today and I was able to actually try my hand at enamil paint I put a dark gray with a tinge of blue base coat on my gauntlet. I will be hitting it with at least one more base coat, then on to the silver. To bad weather is supposed to get cold again so it might have to wait a bit.
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Finally was able to try out the airbrush on the costume and I think it turned out OK I am going to let it dry and put on another coat tomorrow if it is warm enough. This was my first experience painting enamel out of the airbrush over the past few weeks I have attempted some acrylic which I think turned out nice.


Things used today:
- Testors Enamel Paint, picked up from Walmart to practice with before using the humbrol
- Blue (5%)
- Black (15%)
- White (40%)
- Thinner (40%)
-- I hope that all adds up to 100%
- Badger 175 Crescendo Airbrush with medium needle (Needed parts below)
- Harbor Freight Compressor (in garage)
-- Note here if you use a couple long hoses you don't even have to listen to the compressor!
- Harbor Freight Air Brush Hose 10 ft and very soft I like it a lot
- Harbor Freight Pressure Regulator
- Harbor Freight quick connectors
- Gloves (after you clean your parts you shouldn't touch them before paint)


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Well I did a bit of wet sanding this weekend. There were several more rough spots as can be seen above after I put on a single base coat.

This wasn't that interesting of a task, but as always the video for it will be coming later.

I wanted the gauntlet to be more smooth so I went ahead and got some finer grit sandpaper. Here is the technique I used.

Step 1: Get some water for lubrication (think damp sanding)
Step 2: Sand all over
Step 3: Scrutinize your sanding
Step 4:Sand a lot more

From this point on I will be only handling my gauntlet with gloves on (until fully painted). The weather has turned cold here again so I was unable to get another coat of gray on the gauntlet. Once I spray that and get a couple coats on I will determine whether I move to the next coat which I think will be a silver I haven't fully decided yet.

No real pictures from before I started sanding as the post above shows those.

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Hey I've been watching your progress all along, you're doing quite great. I really love those people who go and make it themselves. Keep up the good work.
 
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Thank you. I am pretty happy how it is turning out, the videos take a bit of work, and don't seem to get a lot of views, but I am really enjoying the whole process. I am gwtting frustrated I can't get that right gauntlet done because of all the cold here.
Hey I've been watching your progress all along, you're doing quite great. I really love those people who go and make it themselves. Keep up the good work.
 
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Here is the video of the last sanding effort from above. Really if I were picking my best video this one would DEFINITELY not be it. But I am trying to catalog here :D.

I also started on the left gauntlet, but I am working to make it a longer, but more complete video from the get go.

 
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Big update today. Work finally slowed down enough for me to get some work done. So I completed the main shell for the left gauntlet. There are still little things to do here and there, but I am very happy with how it turned out and how quickly I was able to get it done.

What I used:
- Sintra (3mm thick)
- Razor Blades
- Hot Glue Gun & Hot Glue
- Heat Gun (Harbor Freight)
- Dremel
- Templates (WoF, TheDentedHelmet.com)
- Straight Edges
- Pencils
- Various Clamps
- Sand Paper (220, 500, and 1,000)
- Extra boards to keep edges from bending and set up the bottom template
- Magnets (6x rare earth strong magnets I had laying around)
- Cordless drill and drill bit


Steps to make the Gauntlet:
Step 1: Look at the reference photos and save some to you device so you can look at them while working
Step 2: Print out the Templates (Save them after you cut them out, do not lose them like I did)
-- Make sure to print them the right size
Step 3: Transfer Template shapes onto Sintra
-- I found a pencil to be more than adequate here
Step 4: Cut out Sintra (rough cut then smooth)
-- This could be done with either razor blade or Dremel
-- Dremel is MUCH faster, but causes a TON of dust
-- After the rough cut make sure and clean up the edges with sand paper and razor blade
-- The clean up cuts can be accomplished by taping the saved templates back to the table and laying the rough cuts on top (or laying the template on top) and cleaning up all the cuts with sand paper and razor blades
Step 5: Bend Sintra into shape
-- I did this using a heat gun, and straight edges such as wood to give clean bends
-- Reference photos come in VERY handy at this step
-- I always cut small recess cuts on the back side of a bend to make the bend more square I don't know if it actually works but I think it does
Step 6: Start attaching the bent pieces to each other
-- There will always be trimming that needs to be done in order to get the parts to sit right
-- I had to do quite a bit of trimming to the valley piece that the rocket is to sit in on the top of the gauntlet
-- I just used hot glue to attach all of the pieces
Step 7: Trim all edges and remove excess glue
-- I didn't do this for the last gauntlet before I primed and I could IMMEDIATELY tell where the glue was and had to overcome all the misjudges edges with bondo
-- I didn't get video of this I instead sat down and watched an episode of the X-Files season 1 while doing this part I took a picture of all of the pieces I trimmed off of the gauntlet
Step 8: Add Bondo, let dry, and sand
-- Lather, Rinse, Repeat as necessary
-- I estimate that to get a good part I have to do this step at least 3 times
-- I hate sanding
Step 9: Bend bottom section to flushly connect to upper section
-- Don't forget there will be a flame thrower to attach so give yourself some mounting room.
-- I made a jig to help with the bending it helped quite a bit
-- I let the part get very malleable before I started trying to shape it as the sintra was 6mm thick
-- I heated both sides of the part I was going to bend because it was so thick
-- Getting this to sit right takes time, patience, and a plan going in
--The jig was made by using the WoF templates for the bend then suplementing them with measurements on the inside of the upper portion of the gauntlet so the outer edges would align
Step 10: Add the hinge
-- The hinge was recessed into the bottom part of the gauntlet not the upper part, and was secured with hot glue
-- The hing was purchased from Home Depot it was their 2 or 3 foot hinge, nothing special about it was hanging on the wall beside all their specialty hinges
-- Ensure you measure the length you want the hinge to be before cutting the hinge down
Step 11: Adjust the other side's flushness now that the hinge is attached
-- I had to bend the bottom portion out to give a flat surface, and had to remove some material to allow the gauntlet to close flush with the upper part across the length of the gauntlet (this took many attempts on the right gauntlet)
Step 12: Add Magnets for closure
-- I sunk the magnets using a drill and drill bit slightly larger than my magnets
-- I added an extra square of sintra at each mounting point because it cause a slight warping on the outer layer of the right gauntlet and I wanted to give myself a margin on this gauntlet
-- After gluing the extra sintra square in place on the bottom part of the gauntlet I added the pilot hole for the magnet, placed glue in the hole, added the magnet
-- Added the magnets to the top portion sintra squares, taking care to drill my hole directly into the center of the squares
-- Checked polarity of magnets and marked the side that would be inserted into the pilot hole
-- Glued magnets into upper sintra squares, after drying set them on the bottom part, and closed gauntlets to see how close they were (very close)
-- Open back up gauntlet add glue to the upper squares one at a time, close gauntlet and clamp squares in place, allow glue to set (repeat 2 more times)
Step 13: Enjoy wicked cool Gauntlets!


So I still have to make the flamethrower, figure out what I am doing for the keypad, one more round of bondo most likely, and paint, this is still a long way from complete but hopefully this will help someone, someday.

Video:

Photos:
Step 2:
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Step 3:
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Step 4:
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Step 5 & 6:
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Step 7:
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Step 8:
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Step 9: (Not a lot of action shots taken here)
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Steps 10-13:
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A preview of some work I was doing today. I started attempting the gauntlet darts with a dowel I found at my house. I put my cordless drill in a vice and then locked the dowel in. The rest was done with files, sandpaper, and razors. The middle calls for 1.2mm, but I did 2.0mm because I don't think the dowel will go that small without breaking. What do you think?

Failed first attempt
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Second attempt much much closer to the needed size.
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The darts aren't perfect, but I do think they turned out well. I am like always putting together a video of how I made the darts. It will be probably the most amazing video on youtube ever. Actually Project Binky or Epic Sax Guy (10 hour loop) would also be amazing!.

Tools & Supplies Used:
- 6mm dowel
- Razor Blades
- Sand Paper (60, 120, 500, and 1200 grit)
- Cordless Drill
- Hacksaw (could have used the razor blade)
- Pen (for making marks)
- Measuring caliper (for width and length)
- Clamp (to keep the drill running)
- Bench Vise (to keep the drill stationary)


Method:
1. Prepare the work space
- Place drill in vice
- Loosen drill chuck
- Insert dowel
- Tighten chuck
2. Cut dowel to length
- Measure to front of dart (43mm)
- Mark front of dart (pen)
- Clamp drill running (dowel should now be spinning)
- lightly place hacksaw in position to cut dowel
- Cut Dowel
3. Bring dart width down to 3mm overall
- Rough shaving can be done with a razor blade
- With ~ 0.5mm to shave switch to sand paper (120 or 500, 60 was almost too much)
- Smooth surface with 1200 grit
- Note: Shave with the razor slowly so you don't accidentally take to much material off, or cut clean through the dowel
- Note: Alternate method use 60 grit sandpaper to shave down then step to the higher grit paper)
4. Add the front tip
- Measure back 5mm (the size of the tip)
- Using 120, then 500, then 1200 grit sand paper, make the front a point ~ 45 degrees
- Note: It will not be the entire 5mm it will be less than half of that
5. Add the recesses
- Note: There are 2 or 3 recesses depending on how you make the dart, 1 is 7mm and starts 5mm from the dart tip, the others are integrated into the tip
- Measure and Mark front and back of recesses
- Using razor trim down to slightly wider than desired width (I used 2mm)
- Use sand paper to smooth recesses.
6. Paint
- I haven't done this part yet.

Pictures:
Failed first attempt shown above.

Second dart and subsequent darts.
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Well I decided to put a coat of silver on the gauntlets and as I came here to post this I realized I should have painted the darts from the post before. Ohh well. I will get them next time I have out the air brush.

I went ahead and only put the metallic silver on top as that is where the lion share of the "damage" or weathering is at on the gauntlets. The next coat will be the green over the top. I will be using masking fluid to mark the parts where the weathering will show through. After that I will paint the small parts that are black and other colors. I didn't post any pictures or take pictures of me laying down the base grey/blue color sorry. You can see the color on the bottom parts of the gauntlets. I had drifted away from the purpose of this build which was never going to be up to 501st quality, so I had started slowing down. I have decided not to seek that any more so I should be able to move a bit quicker, but also have a very nice costume when I get done. Also I printed all of Rafal's templates for the helmet I am going to try and get some 2mm chip board and start that process soon.

Left Gauntlet:

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Right Gauntlet:

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They're pretty nice looking, good job on those. Can't wait to see them completed!
 
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Well weather keeps me from painting the gauntlets. So I decided to start on the helmet the question is should I start a new thread for the helmet build? Rafal Fett has a fantastic template, but I have a crappy set of scissors and my hand is cramping.
 
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I don't know what forum protocol is, but I'd be more apt to follow if you kept it all in one thread. :D
 
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Well some updates, I put the base coats of green down on the gauntlets. Now I just need to add the darts and detail the small pieces. I am letting them dry a couple days before I do anything. When I took this picture they were still drying.

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Ohh and I started the helmet work in earnest today. Got some large parts cut. I still have to cut the base of the domes. I was thinking about using Thinner cardboard for the inner support portions. I am a couple days out from starting shaping. I haven't decided on what glue to use either, any suggestions are welcome! Thanks Rafal for the templates!

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Now the fun starts! FWIW, I used elmers glue. It takes time to dry, so I would glue and tape something, come back to it the next evening. Worked well for my schedule.
 
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Now the fun starts! FWIW, I used elmers glue. It takes time to dry, so I would glue and tape something, come back to it the next evening. Worked well for my schedule.


Thank you for the tip. I have been kicking around how to do it for the past couple days, but I have been cutting and not worrying about it yet.

Also I just realize I should have put the split under the ear piece rather than the back of the helmet.
 
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Thank you for the tip. I have been kicking around how to do it for the past couple days, but I have been cutting and not worrying about it yet.

Also I just realize I should have put the split under the ear piece rather than the back of the helmet.

I personally use hot glue since it holds well and drys in a few seconds, and you can feel it off if you feel the piece is not in the right spot, but it's your preference. Just my two cents.
 
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