General WIP ESB Boba Fett; scratch build progress updates

Nice!!! Looking forward to seeing pictures! I love a good scratch build.


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Here's a pic of the toe spikes installed, but before I masked off the canvas and filled in with white Titebond caulking. It's similar to polyurethane and will take paint, etc. I wanted to install the spikes before applying the piping to the boots, since the piping pretty much goes to the ends and bends in the toe spike plates.

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Here's a pic of the boots after applying filler around the toe spike plates.

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I'll post another pic after drying and trimming/cleaning the filler.

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Got my ammo belt done today. I followed RafalFett and Strumfett's tutorials.

First I cut blocks, I made mine from tight knot cedar; light, easy to cut and smells good!:
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Made a pattern:
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Here's the pattern cut out:
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Pattern transferred to the back of some antique brown vinyl, $10/yd.
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Block wrap applied with hot glue, strap pattern behind it:
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Strap cut out, but before sewing:
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After sewing, I used light gray upholstery thread, and installed with hot glue:
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I finished the blocks and belt yesterday, then today added snaps, velcro and grommets:
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Still need to fix the pouches when I dial in their positions, weather it and add the cargo pockets. I plan to make the 2 pouches that have snaps actual usable empty pouches, but that will come later. I have a ton of vinyl left over, and could make 2 more belts. Between this and my girth belt I'm very pleased. Gotta get on those boots!

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Nice! I did mine a similar way, but I forgot to cut the straps wide enough to fold over :(
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Nice! I did mine a similar way, but I forgot to cut the straps wide enough to fold over :(

Cool material, I almost used a material like that. Instead I got some that was kind of caramel colored, and planned to dye/paint it. Then I found this darker mottled stuff I ended up using, I got it at the local foam/fabric outlet. The fabric store took back the lighter stuff.
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WIP ESB Boba Fett costume build; detail pics

Nice that stuff is perfect! I have yards upon yards of the stuff I used. I make Tusken bandoliers with it.


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I created two functional pouches for my belt last week. I made hollow boxes from some 3mm sintra I just got, partly as a way to see how this it is to work with the sintra, and to test my planned adhesive. I used the same exterior dimensions as my wood blocks, glued the sintra with all-purpose plumbers cement for PVC. The cement has more body than regular PVC cement, and is opaque so easier to see where you've put it.

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Here's the boxes/pouches, one wrapped in vinyl one not. Light and sturdy, I rounded the outer corners just as I did the cedar blocks I made earlier.

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Done, with snap closures. I decided to make the usable ones the ones with snaps. The pouches can almost, but not quite, hold 2 9V batteries. They could if I trimmed the vinyl. At first I though I could use a magnet on the base, but of course the snap is brass so the magnet idea wouldn't work unless I used them on both sides. My other idea was to make the front-most pouches the usable ones, we'll see how this goes.

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Re-dyed my girth belt, it wasn't dark or red enough. Part of the problem was I was using the small cans, and thinning with paint thinner, which made the stain less dense and also made it take a very long time to dry.

I got some Barn Red Varathane stain and mixed it with the Cabernet I already had.

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The results; before, after, outside:

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I'm pretty pleased with the results. Pretty soon I'll have to suit up and see what a difference all these small improvements make.

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Baby Steps... Purchased helmet fans, chest display, viewfinder lights and servo.

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Also started adding piping to my boots. First go, the glue didn't hold. Sanded the waxy finish of the leather piping to better stick, I hope. I'll stitch the piping at the ends for good measure. Next up, weathering and coloring.

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Finished my boots! They're not 100% screen accurate, I know, but I think they're good enough. I ended up giving up on the leather piping, as it wouldn't stick. I got some thicker, cloth-covered "parachute cord" that worked great. I painted the sides of the soles white, then the center strip on top dark gray, and then weathered them with dark gray and black. I scuffed and marred the paint and toe spikes with a sanding block. Then I finished by hand-stitching the top end of the piping over and through the top edge, in an effort to prevent them from coming loose with constant on/off abuse. What do you think?

Before:

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After:

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Nice man those boots look great! It could just be the lighting but you might want to go a touch darker in the middle just my 2 cents!


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Nice man those boots look great! It could just be the lighting but you might want to go a touch darker in the middle just my 2 cents!

I agree. The contrast was good before I weathered the boots overall. I'll go back and darken the center stripe with black. I might lighten the soles too.

nice job you've done on the boots.

Thanks, took me forever to get them done.
 
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Last night I started the viewfinder prism. I bought a 6" x 6" slab of 1.25" thick clear acrylic from Tap Plastics in Seattle for $36 incl. shipping. On my table saw I cut it to size, and am sanding it using a sanding sponge to remove sawblade marks and to give it a uniform haze. Anyone know if it's supposed to have recessed lines on the top (hidden) side? Looks that way from Alan Sinclair's helpful templates which I'm using. There are green lines that suggest that in the PDF illustrations.

Acrylic block:
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Cut to rough size:
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After some sanding (but not done):
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