Stormcrow 85's WIP: Boba Fett - ESB

Stormcrow85 · Oct 19, 2015

Alright I have given my introduction in the intro section, but wanted to post up some work that I have been doing. I have always wanted to make a costume, I decided that I would do Boba Fett as my first costume. In hindsight probably should have gone with something else that way I could see if I was any good at this. Some introduction to my project.

I have no formal training in sewing. My mother always sewed when I was growing up, and my wife has a sewing machine that she was given that she doesn't know how to use. I decided I could use this thing and make a costume. I leaned towards Obi-Wan, but my hair is to short, and I can't grow a beard. So I decided Lando Calrissian but figured some people might find that offensive (I am white, and thought it would be HILARIOUS). Anywho, I on a whim decided Boba Fett because he looks totally Bad-A!

I come from the car world and have been doing timelapses of my work on my car for several years. I decided that I would do it for this too. I have had a very easy couple of weeks because the wife has been out of town with the kiddos and I have been home alone after work. So below is my first video. I went yesterday and added an intro to several already made videos. I hope you enjoy. Only the first two videos have music over the time lapses the rest are just silent. The goal is to eventually add annotations over the top to show what I was doing.

Video 1:
I started this project by looking online a TON to see about high resolution pictures of Boba Fett. I decided on the color and went out to buy fabric. I got home and realized I really needed a "flight suit" rather than just pants and a shirt so I made a flight suit from really no pattern, but just looking at one I had on hand. This video I made a bit to fast so I slowed down the next few videos as well as changed the camera angle.

Stormcrow85 · Oct 19, 2015

In Part 2 of my videos I continue making the flight suit.I had to do SO much seam ripping because I didn't do a good enough job separating the front and back of the garment as well as had to try and figure out what to do about the color. Here is where I made my first change from the movie. I didn't like the idea of a neck additional collar I would think that his flight suit should have the neck seal collar so I decided to add it to the flight suit rather than a separate piece. I added strips of batting to the collar and had to make it much tighter fitting because I have a pencil neck.

View attachment 93002 View attachment 93001

The picture on the right shows before I added the collar, the picture of me on the left shows after I added the collar. The flight suit was almost done, but I still needed a collar and pockets (I still haven't added the shin pockets at the time of writing this)

Stormcrow85 · Oct 19, 2015

In video 3 which is quite a bit longer. I added the collar, as well as the pockets. I learned quite a bit, but still made some annoying rookie mistakes. Which included a TON of seam ripping. I also took in the pants and several areas much tighter than what they were I could have probably saved quite a bit of material if I would have done a better job making my legs smaller. I also wasted some material when I made the sleeves literally to small for me to fit my arm in (Which I had to laugh at, because my arms aren't that big). If I were to do this again I would keep the neck seal on the flight suit but I would do it in the white material so it would be more "movie accurate".

The video: It is quite long, it was a very long day.

Stormcrow85 · Oct 19, 2015

So after the flight suit I went right to work on the flak vest. I used some pictures from the internet and drew a pattern on the material. It turned out almost perfect. The only problem is the front doesn't have a wide enough shoulder piece, but other than that I like it. Also I really wanted to make it zip from the side, but couldn't find a short enough zipper when I was out and about that day that fully separated. I still have to add the panel to cover the Zipper in the back, and a real pull string to it. I works how it is right now. I also didn't get any video of making the sleeves, but pretty much I made sleeves, doubled with batting for padding , then I positioned them in the sleeve until they pointed in the direction I wanted them and sewed them on. I hope you enjoy the video and pictures.

Here you can see the gap, that exists, but can also see the flight suit.

Here is a picture of the vest on with the little sleeves:

And here is the timelapse.

Stormcrow85 · Oct 20, 2015

So the fun part started. I got some expanded PVC foam (sintra) from a sign shop (FastSigns) it was remnants and the young lady working the counter just gave it to me. I got enough there to do the chest, shoulder, and waist armor. I did not have enough to do the knees, back armor, or gauntlets (If I use it to even do those). I have since purchased a heat gun and lots of other little nick-nacks. This project is being done on the cheap, but it is really starting to nickle and dime me. I used the templates from this site, laid them out on the sheets and then started cutting it out with my dremel. I am on a business trip so the back drop of the next several videos is a hotel room, luckily it isn't tiny.

Pictures:
Template testing on vest, I wish I would have tested the collar I didn't think about it, but I did almost everything else.

Laying out the templates

And Cut out!

Video:

Stormcrow85 · Oct 20, 2015

After I cut out the pieces I noticed there was quite a bit of sanding that needed to be done to clean up the edges. I also used that opportunity to bevel the edges as well on the corners. There isn't much to say about the process. I got some cheap sandpaper from Harbor Freight when I picked up the heat gun, and the whole time wished I was at home where I have an orbital sander I could have used to make short work of the pieces, but when you are 500 miles from home and in a hotel room you make due.

The before picture of the edges of the shoulder pad:

This is after I got done sanding:

The video:

Stormcrow85 · Oct 22, 2015

After I cut the armor out I started shaping it. It wasn't that hard to shape the chest, stomach, and shoulder pads. The collar and cod piece were not as easy, but I think all turned out well. After I shaped the pieces I added pock marks and large dents to the items.

Here are some photos of the newly shaped pieces.

Video:

Silverstalker · Oct 23, 2015

Its one thing when someone posts still pics of their progress but when you see a video or 6 about the whole design and construction it puts it all into perspective about how much effort and skill can go in to making a Fett outfit. Bravo Sir nice work.

Darth Voorhees · Oct 23, 2015

This is incrediby awesome work bud! Like Silverstalker said, showing all the steps really shows how much work goes into making these things. Sometimes justifying for some the cost and wait time of someone having something like this made for them.

Some constructive criticizim for you...not negating anything you did, because its fantastic! So, 2 things...1 you are actually correct about the neckseal being attached to the collar. That is how the flightsuit was in the film. However it should be the same material as the vest, and not the blue color. The other thing is the pocket flaps should just be diagonal, without the notch you put one em..though i like that look and may steal that for a custom mando

..oh and you need to add the shin tool pockets, but you may already know that.

But like i said, this is great work, and awesome you posted video of the whole process. I really wanted to do this when i was making my jetpack, but it took to much extra time to set up a camera, remove it from the shop for sanding, and re-setting it up.

Malkavian · Oct 23, 2015

I recommend you make your COD piece from three pieces, Main strip, front plate, and bottom cusp. By separating the bottom cusp you will be able to achieve a better profile

forgive the focus

Stormcrow85 · Oct 23, 2015

Thank you all for the comments. I am going to go out today and try and find some burgundy dye for the belt I am making. The first belt I made was WAY to small I measured once then cut 14 times (Not the way to do that just so you all know, measure each one).

Silverstalker said:
Its one thing when someone posts still pics of their progress but when you see a video or 6 about the whole design and construction it puts it all into perspective about how much effort and skill can go in to making a Fett outfit. Bravo Sir nice work.

I most certainly underestimated the amount of work that goes into a build like this. The only reason I got so far is because my wife and kids were out of town for fall break, but I had to stay for work. Then work sent me out of town for 10 days. I just got home today. So progress will slow. Also it takes me a while to make videos, but I want to keep this somewhat orderly so I didn't just do a complete data dump I am several more days into the project.

Darth Voorhees said:
This is incrediby awesome work bud! Like Silverstalker said, showing all the steps really shows how much work goes into making these things. Sometimes justifying for some the cost and wait time of someone having something like this made for them.

Some constructive criticizim for you...not negating anything you did, because its fantastic! So, 2 things...1 you are actually correct about the neckseal being attached to the collar. That is how the flightsuit was in the film. However it should be the same material as the vest, and not the blue color. The other thing is the pocket flaps should just be diagonal, without the notch you put one em..though i like that look and may steal that for a custom mando ..oh and you need to add the shin tool pockets, but you may already know that.

But like i said, this is great work, and awesome you posted video of the whole process. I really wanted to do this when i was making my jetpack, but it took to much extra time to set up a camera, remove it from the shop for sanding, and re-setting it up.

I realized after I made the collar that I should have done it in the vest material. I wanted to wait to finish the vest before I cut the collar off. Great catch on the pockets. I thought it was squared at the top too. it isn't. I could fix it, but I am going to keep it as it will help me make the pockets more functional. as that is where I plan on storing stuff like my wallet. The shin pockets will hopefully get made I had to abandon all sewing for the last 10 days as I have been out of town. I am back now and will be makign them probably this weekend, along with the correct color of collar.

Malkavian said:
I recommend you make your COD piece from three pieces, Main strip, front plate, and bottom cusp. By separating the bottom cusp you will be able to achieve a better profile

forgive the focus

That is awesome. I am way to far past to cut it off and start again, but thank you for the tip. I also should have spent more time with the bondo smoothing to be honest I got a little excited, and therefore impatient.

Stormcrow85 · Oct 24, 2015

Malkavian. Here is the reason why it was no good getting the advice about the three pieces. This cod piece work was done almost a week ago, I am just getting around to writing the post.

The cod piece shaping could have been accomplished better another way. But live and learn. I built up the buttons using two layers of pvc sheet. If I were doing it again I would have done the intelligent thing and put another layer of Bondo before painting. As I have said before, I have a bad record with patience I just want to get this done so I move too quick sometimes. I still haven't fully decided how I am going to mount all of these things to the flight suit. If anyone has any suggestions I am leaning towards velcro, or snaps. I think velcro would be easier, but I don't know if everything will stay put. Don't want to loose the pieces while I am walking away. The pictures above make it seem like I did the cod piece work at the same time. I actually did it a day or so later.

I know the videos are getting longer, but I am doing a bit more explaining in the beginning.

Video:

BennaBuildsBoba · Oct 24, 2015

If I may ask. It looks like you used the WoF templates, did you select your size and print to fit the page? I'm building a suit for my 7yr old and eventually will upgrade him, but I'm going with a "cheap" build so I can get the hang of it.

Stormcrow85 · Oct 25, 2015

BennaBuildsBoba said:
If I may ask. It looks like you used the WoF templates, did you select your size and print to fit the page? I'm building a suit for my 7yr old and eventually will upgrade him, but I'm going with a "cheap" build so I can get the hang of it.

I went to the template page and selected the pre-sized template based on how big I am. The WoF templates can be sized by changing the scaling feature in Adobe. The way I would suggest doing it is print out a test page or two using different scaling on certain parts (Shoulder, collar, stomach) if those are close then the rest should probably follow suit. So perhaps measure your child and yourself in the torso and scale the templates appropriately.

Good luck!

Stormcrow85 · Oct 25, 2015

Alright here is my first Girth Belt failure. I didn't standardize the lengths and I didn't attach them to a D-Ring. I have since made another, but the dye did not stick at all. I didn't think this was going to be the hard part. I should have the paint video up in the next few days as well. I will discuss the painting there.

I used TK409 website as a suggestion to make the girth belt, but I didn't get pure cotton rope I instead got a polyester cotton blend. I tried dyeing it but didn't have a stove to keep it hot, so the dye didn't stick, also when I got it all put together it was about 3-4 inches to short. So I will be re-making the belt. This was not a hard project but unfortunately it was a HUGE waste of my time.

I also made the color strip for canvas ESB cape. I still need to sew it all together which won't take much time at all. No pictures this time only a video of my failure.

Video:

BennaBuildsBoba · Oct 27, 2015

Stormcrow85 said:
I went to the template page and selected the pre-sized template based on how big I am. The WoF templates can be sized by changing the scaling feature in Adobe. The way I would suggest doing it is print out a test page or two using different scaling on certain parts (Shoulder, collar, stomach) if those are close then the rest should probably follow suit. So perhaps measure your child and yourself in the torso and scale the templates appropriately.

Good luck!

Thank you! It took some time to get them a little smaller, but I think we got the right size. I'm making it out of foam it seems to be more forgiving and if I mess it up I have more! I'm kind of hooked now and I want to build one for myself. Mom and son Boba?

Malkavian · Oct 27, 2015

I still haven't fully decided how I am going to mount all of these things to the flight suit. If anyone has any suggestions I am leaning towards velcro, or snaps. I think velcro would be easier, but I don't know if everything will stay put. Don't want to loose the pieces while I am walking away.

I haven't attached my plates to the flak vest yet but I was leaning toward magnets. I know a guy from the 501 who used Velcro and has no problems. I don't know if its the Velcro I bought, but from past projects I find the Velcro attraction is stronger than the backing glue so whenever I remove stuff it just peals the Velcro off. Obviously sewing the Velcro into the clothes prevents one side from pealing but the armour sides still peals.

xanthis02 · Oct 27, 2015

If you use super glue on your velcro they won't peel off

Stormcrow85 · Oct 27, 2015

Thank you for the tips Malkavian and xanthis. I am leaning towards velcro as well for this build these pieces aren't very heavy. I have done quite a bit more but it is getting to be harder separating out the projects. I might have to go to just a this is what I did today type video rather than separating it all out into different pictures as I have been working on several parts at once.

In today's video I added the battle damage using a heat gun and just a sharpie to dent the pieces. It was not that difficult and it was the last step before painting. I have since painted and repainted the pieces several times as I went WAY overboard on the amount of "weathering" I applied to the armor.

The denting technique was not difficult the heat gun and pressing the piece to me worked wonderfully. The battle damage is done with masking fluid I first bought from hobby lobby for $15 then found at Walmart for $7.50 so I took back the hobby lobby stuff. You can see in the video I already have the primer, silver, and yellow coats of paint. If you look closely I did the masking video after I did the de-masking video. I think it worked out pretty well. But I had to tone it down ALOT. I figure the paint video should have probably come firs, but I will finish that one in a couple days because I still haven't finished all the painting.

Pictures: