I've been cruising the forums for a few months working on this, then I ran into Asok over Fourth of July and he convinced me to stop being a lurker. I'm in the process of building a Boba and a Jango costume for my six-year olds. Thanks to Wizard of Flight for his awesome templates, Fett Full of Dollars for the trash can armor idea, and Stormtrooper guy for his rattlecan colors. The costumes aren't 100% accurate, but hey they're for kids, and I gotta get two of these things done by Halloween! Also, I made a few adjustments for safety/durability once they start playing in them.
The armor is trash can. The helmets are signage, fiberglass, and Bondo. The "ears" are MDF (I got a little excited late one night, and accidentally epoxied the right ears on before I filed the edges down). The gaunt bases are PVC and the tops are MDF sections epoxied together. I cut the left gaunt short in case a hand got snapped back in a fall. The knees are PVC with MDF dart blocks and dowel rod darts. The ammo pounches are craft foam. It's a WIP, but I wanted you to see what I have so far. Thanks for all the help!