My son has shown interest in building another suit so this will be a project we tackle together. We started with some gelcoat pulls of BKBT armor and went from there. All of the upper body pieces were reduced to a .75 scale of the BKBT parts. The leg pieces will be reduced to .85 scale to allow for trimming. We should have the shins and shoulders done in a few days, however, both the cod and backplate may prove to be tricky. My hope is to mold the pieces so vac-form bucks can be created for producing light weight and economical armor for our little Jangos/Mandos here.
Let us know if there are any suggestions or recommendations.