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  1. thksdad is offline thksdad
    Jul 24, 2008, 1:30 PM - Fett Mannequin With Progress PICS #1

    So i really haven't been in the Fett scene lately so im really excited to be back into it. This time, im making a Jango Fett costume...mostly for an awesome display but also for fun convention times... Anyway, i was shopping around here in B'ham and saw that the local Goodies was going out of business. I went in there hoping to get some great deals on a few shirts but sadly they didn't have much of a selection. LOL. so, i started to leave when i saw a row of mannequins all for sale. I went over there and saw that the full mannequin displays with stand and arms were only $50 out the door! I was so stoked. LOL. Long story short, I bought the mannequin and wanted to mod it for my Jango outfit. So, I posting this for those who would like to do the same. Im winging it to be honest So...Here we go....

    Here are all the materials I will be using. Materials were a little less than $50. I got fiberglass resin with the harderner (usually comes with the can but check), fiberglass cloth (the cloth makes it a lot stronger and will be easier to mold), a box of gloves, plastic tarp, gorilla tape, a few $0.92 paint brushes (get cheap ones), and be sure to get a mask. I already had one so that wasn't in the $50 quote.



    *Step One- Be very Patient. Do not rush things and try to have some fun with the project. Remember, you can always fix something if you mess up so try to relax and enjoy the projec.

    *Step Two- Buy the mannequin of your choice. Mine was made from fiberglass which makes it so easy to work with. Take it to a good open area with plenty of ventilation. You will be working with fiberglass which is very strong and could be harmful if used in an inclosed area. Place the mannequin on the stand and cover the enitre stand with paper and or masking tape. I did both just to be extra safe. Decide on how you want your mannequin to look ie his or her pose. I started with the leg but will mod the rest later.

    *Step Three- Mask off the area you will be cutting. This will give you a clean cut and will keep you from cutting too high or too low for the connecting line. You can use a dremel or a saw. i used one of these.



    I already cut the leg off at the knee cap so I didn't get a complete pic of what the mannequin looked like before...





    *Step Four- Play with the leg to get it to the position you would like it to be. It takes a little looking at at different angles. Just mess with it until you get to a look you like.



    *Step Five- With the Gorilla Tape, tape the leg into the position you would like it to be in. I started off with a couple strips just to make sure thats where I wanted it to be.





    *Step Six- Next cut strips of the Gorilla Tape and tape the leg into position. I used about 6-7 strips. You do not have to tape up the whole leg, but that would be up to you. This just keeps the leg into position and will give added strength for the leg.





    *Step Seven- Next comes the kinda tricky part. If you have never used fiberglass its very simple. Its basically adding the correct amount of resin to harderner, stiring, and applying to the cloth. Instructions are on the back of the can. However, I usually just eyeball everything. You will need a bowl (I used a recycled butter bowl. You can use a disposiable cup or whatever you would like), a paint brush (the very cheap ones), the fiberglass cloth, gloves and YOUR MASK.



    ...and don't forget your Milos Sweet Tea. Your mask doesn't have to be the one I have but you do need something. The cheap white ones with the nose pinch clip will do just fine.

    Start by unfolding the fiberglass cloth like so...



    Then cut 2 (roughly 5-6") strips. Enough to wrap around the entire leg.



    Do a quick test fit to make sure they make it all the way around or close to all the way around. Mine was about 1" shy of connecting.



    *Step Eight- Now comes the Fiberglass part. Make sure you are wearing your mask and your gloves. Pour some of the fiberglass resin into a bowl (again, make sure its not valuable ).



    Add in the correct amount of harderner. If you add too much, thats okay. The more you put in the faster it will cure, or dry. This can be a good thing if you don't have much to do, however can be bad if your taking your time. Take your brush and mix the resin and harderner. Make sure that its mixed well. If its not, it will not hard. Then, Take one strip of the cloth and hold it in the middle of the seam. you want about 2-3" of cloth on above and 2-3" of cloth below the cut you made. Take your brush and apply the mixd resin to the cloth. the cloth should almost become a yellowish/ brown opaque look. That means you have a good amount of resin on the cloth. Simply mold the cloth to the body. You can leave the cloth higher in some areas for more realistic "knee cap" areas but doesn't matter. A jumpsuit will be covering up all that. Here is the finished knee with the fiberglass. I put 2 sheets on it. This makes it stronger so it will not break off.









    Thats it for now. I'll try to work on it again in a few hours and will be sure to post more pics and steps.
    Last edited by thksdad; Aug 4, 2008 at 4:06 PM.
  2. runJEDIrun's Avatar
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    Apr 2007
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    Jul 24, 2008, 1:31 PM - Re: Fett Mannequin With Progress PICS #2

    great progress pics. can't wait to see the results!
  3. thksdad is offline thksdad
    Jul 24, 2008, 9:19 PM - Re: Fett Mannequin And Jango Parts **Updated 8/4 #3

    *Step Nine- You don't have to do this but I did. I put a layer of blue Painters Tape around the resin. Sometimes it can still be a little stickey from the resin not getting completely mixed. The painters tape helps when working on it so you don't always have to wear gloves. It also adds structural support and a cleaner finish.



    Then I put a layer of Gorilla Tape on it to add structural support.



    *Step Ten- The Head. Now, my mannequin is goning to have the Jango Fett helmet on it so it really doesn't matter what my head looks like. I went to Party City and grabbed a styrofoam head for a little less than $2.00. I also pick up two nice size tubs of Plaster of Paris. I will be making a mold of the head and fiberglassing the head for extra strong support and so i can make copies if i'm not satasfied with the first few.





    For this you will need a trash can (deep enough for the head to fit in without touching the bottom), a trash bag, gloves, plaster of paris, water (I put mine in a watering can so I don't have to go inside every two seconds) a mixing bowl, and a paint stir.

    *Step Eleven- Place the trash bag into the trash can. This prevents your trash can from getting plaster of paris on it. Get your mixing bowl and water and add two parts plaster with one part water. I used one tub so I mixed all the plaster with half a tub of water. Mix it well. If you use your hands it is easier to mix all the big clumps of plaster. This is why i'm using gloves. Plus it sucks to pick plaster out of your arm hairs. LOL. Pour the plaster into the trash bag. Pull the bag tight to avoide wrinkles in the plaster and risk messing up the mold. Then push your mannequin head into the plaster. Make sure the head touches the bottom of the can and then pull it up slightly. this will create a good lip for your mold. You will need to add some weight to the top. My extra plaster tub was just the correct weight. I used a paint stir to balance the tub.





    You can see the bottom of the chin on the last pic. I will need to mix a tad more plaster to fill the neck up to the top. Hope yall are enjoying the Progress pics. I'm doing it for you guys.
    Last edited by thksdad; Aug 4, 2008 at 4:05 PM.
  4. thksdad is offline thksdad
    Jul 25, 2008, 11:42 AM - Re: Fett Mannequin With Progress PICS #4

    *Step Twelve- Removing the styrofoam head. I used a fine edge saw to get cut open the plaster. this gives a cleaner cut and makes it easier to work with when fiberglassing. Start off by takin out the mold from the trash can. It requires a little bit of work.







    Then with your saw, start making a clean cut down the middle. I endd up cutting both sides, from the top and from the bottom. Trace your lines so you get a strait solid line as done here. You may need to cut the stub of the neck off in order to make the mold flat as i have done in the pictures.









    Once your mold is cut into two peices, you need to remove the styrofoam head. This takes time and is trickey/ frustrating. LOL There really is no meathod for this. I used everything from a lighter to help fold the edges down, a grill poker, and anything of the sort. Be sure you do not go too deep when picking the styrofoam out. You could possibly damage your mold which would not be good. If you can get something under majority of the styrofoam it should just pop out.









    Once you get the styrofoam out you are now ready to make your molds.




    I'll Post more pics a little later...
  5. KaanE is offline KaanE
    Jul 25, 2008, 11:49 AM - Re: Fett Mannequin With Progress PICS #5

    Quote thksdad said: View Post
    I'll Post more pics a little later...
    I want more pics NOW!
  6. thksdad is offline thksdad
    Jul 25, 2008, 11:54 AM - Re: Fett Mannequin With Progress PICS #6

    Quote KaanE said: View Post
    I want more pics NOW!
    Haha....I'll get some up in a little bit. Im makin my dude a head
  7. thksdad is offline thksdad
    Jul 25, 2008, 10:39 PM - Re: Fett Mannequin With Progress PICS #7

    *Step Thirteen- Making your Head. So I went ahead and started to make a mold of the head. Its going to be in two peices and will join them later. Basically rub a TON of vaseline into the mold. This helps the mold come strait out. After you do that, take your fiberglass cloth and fiberglass and go to town. It takes a little more work to make it stick but when it starts to hardern it will stick more.





    After the fiberglass dries, pull the cloth out. It will be a little flexable. This is what it is suppose to do. After the mold is out you will get the fiberglass mat and cover the top of the mold with the mat. Repete the processbut with the fiberglass mat ontop of the face.





    And this is a final half minus the triming of a face...

  8. Cruzer's Avatar
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    Aug 2004
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    Jul 26, 2008, 8:10 AM - Re: Fett Mannequin With Progress PICS #8

    Nice techniques. This would be a good thread for the Probuilding Methods section because I bet there are a lot of non-Jango people who could benefit from your build pics.

    Great work and keep it up!...but I'd like to see Jango gear on that dummy asap!...or else he's just another dummy!
  9. thksdad is offline thksdad
    Jul 26, 2008, 11:14 AM - Re: Fett Mannequin With Progress PICS #9

    Sure thing. I've bought some Jango Stuff so it should be coming in sometime soon. oh and by the way, i'll be shooting you a PM soon for some more Jango Goods
  10. thksdad is offline thksdad
    Jul 27, 2008, 4:43 PM - Re: Fett Mannequin With Progress PICS #10

    *Step Fourteen- Triming the Head. Its really easy. I used a dremel and it cut like butter. Just trace out your lines your going to cut and go at it. I got a little sick with my head.



  11. thksdad is offline thksdad
    Jul 27, 2008, 4:46 PM - Re: Fett Mannequin With Progress PICS #11

    *ATTN Mods- Please Move to the Prop Building Meathods*
  12. KaanE is offline KaanE
    Jul 28, 2008, 5:14 AM - Re: Fett Mannequin With Progress PICS #12

    Wow! You did Tutankhamun

    See here... Nice work
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  13. thksdad is offline thksdad
    Jul 28, 2008, 3:02 PM - Re: Fett Mannequin With Progress PICS #13

    Thats awesome!!!! wow. yea, i guess so. I'm going to paint the head black so it really wont matter what it looks like. But yea, Here is some triming i've done on my mannequin. I'm going for this pose. Kinda maybe...I fliped the image to get it as close to what I want it to look like. Too lazy to get in photoshop and do a nice job.







    The arms are temp till I get back from the beach. I'll fiberglass them when I get back.
  14. thksdad is offline thksdad
    Aug 3, 2008, 2:18 PM - Re: Fett Mannequin With Progress PICS #14

    Okay so I started getting some goodies in the mail and I'm really getting excited. Here are my gloves from Lands End. They were a whole light lighter than I thought so I ran to Walmart and got some Rit Dye- Navy Blue. After they finished drying I cut out the liner cause it really gets in the way. I stitched up the sids to make it cleaner and placed some velcro on the gloves for a tighter fit. I also swed these in to make it hold. Gave it a little weatherd look and boom...Jango Gloves. These pics are with the flash which can really brighten up stuff. the darker ones are without the flash.









    Then After that I started to work on the mannequin. I cut the top of his thigh to give him more of the Jango Stand. Hopefully when it gets clothes on it will look more like the photo. I also fiberglased the arm into pace. Not the cleanest job but its good enough for me.







    And Lastly for today my Jango Boots. I finaly got around to getting the stupid snap buttons on there. and man, they were a pain in certain areas. But oh well, its done at least





  15. tubachris85x's Avatar
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    Mar 2006
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    Aug 3, 2008, 2:48 PM - Re: Fett Mannequin With Progress PICS #15

    Looking cool so far! Going to be the first mannequin that Ive seen posed like that
  16. Aug 3, 2008, 2:54 PM - Re: Fett Mannequin With Progress PICS #16

    Coming along nicely! Can't wait see how it turns out.
  17. TR 4059's Avatar
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    Aug 3, 2008, 4:21 PM - Re: Fett Mannequin With Progress PICS #17

    I love the pose because its different for Jango. Great progress man.
  18. thksdad is offline thksdad
    Aug 3, 2008, 6:12 PM - Re: Fett Mannequin With Progress PICS #18

    Thanks for all the kind words. I'm really excited to see how everything ends up. Anyway, I didn't wana say anything but i'm going to....just a teaser though. Lets just say one awesome bounty hunter needs one awesome platform to stand on. Its still in the works but can you say Geonosis...

    Last edited by thksdad; Aug 3, 2008 at 10:44 PM.
  19. thksdad is offline thksdad
    Aug 3, 2008, 10:42 PM - Re: Fett Mannequin With Progress PICS #19

    well, here are some more pics. I made a mold of my hand, cut it up, drilled a few holes, plugged them with electrical wire, and boom, fingers. it was more work than that. but yea. Here some photos.













    And here i've cut my mannequin's waist twice. I'm going to gradually twist the waist to make it more like the post in the picture. I will fiberglass this later. Got to go get more fiberglass


  20. Aug 4, 2008, 7:12 AM - Re: Fett Mannequin With Progress PICS #20

    Looks great! Think i found a better pose you could do though j/k
  21. thksdad is offline thksdad
    Aug 4, 2008, 9:21 AM - Re: Fett Mannequin With Progress PICS #21

    haha. thats the one!!! im scratching my mannequin, buying another one and making him a fruitcake.
  22. thksdad is offline thksdad
    Aug 4, 2008, 4:00 PM - Re: Fett Mannequin With Progress PICS #22

    Okay so I finally got around to making my Jet Pack Harness. Basically what your going to need is some strap material (black, 7 yards is plenty), 3 Heavy Duity buckels, hot glue/ glue gun, measuring tape, and a lighter.



    Then, make 2 simple measurements. Around your chest and from your mid back to the bottom of your chest.





    Then, cut the chest measruement 10" extra for play room. This also helps if you are to ever sell the harness in the future. A very good tip is to get your lighter and "melt" the ends to seal them up and to prevent them from fraying.



    After you have your chest peice cut, set it aside and cut two peices from your mid back to the bottom of your chest.



    (Mine were overlapping) After you get those cut, simply place a buckle on the chest peice. I ended up glueing one end to keep it secure. The other end is for me to tighten and loosen.





    Then attach the two peices that go to your back. I use Hot Glue. Its quick and easy and holsd really well. You can do this and go back and sew but I personaly hate sewing These are the shoulder straps.







    Then, attach the sholder straps to the back side of the chest peice.



    ***Isn't my baby cute She was like, What the heck is that for...***

    After thats attached, test fit and make any corrections. From here, cut two 12" straps. Seal the edges using lighter and attach them to the shoulders. These will go to the jet pack.





    Thats about it. I did glue my straps in the front and in the back so that they do not move. However, that is a personal thing to do. I like my harness very snugg and others might not. I also added a few "supports" to the harness.



    And thats about it.
    ************************************************** *************
    Also I finished the boot straps. They look a tad blue for whatever reason. Either the vinal was a very dark blue or black

  23. Studio Fett's Avatar
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    Aug 4, 2008, 4:40 PM - Re: Fett Mannequin With Progress PICS #23

    Looking great, man, this is going to be so killer when you're finished with it!

    G-Fett
  24. Aug 5, 2008, 6:09 AM - Re: Fett Mannequin With Progress PICS #24

    Quote Studio Fett said: View Post
    Looking great, man, this is going to be so killer when you're finished with it!
    I second that!
  25. thksdad is offline thksdad
    Aug 5, 2008, 10:33 AM - Re: Fett Mannequin With Progress PICS #25

    Okay, just a little update on the Jango Platform. I really wasnt too into the color of the platform so I went digging around for some old paint in the house and found some interestiing colors. Got a mustard color that I had for a theater room I just finished and some different glazes. One glaze was a brown and the other was Najaho Red... yea, I wasn't sure with the name. anyway, started a few painting meathods and this is what I came up with. Would really like some input. I think the color is okay. Not sure really what it needs. There so many colors in the photos and its hard to get all them. But then again, who really cares?











    And here i'm making the ground part for Jango to stand on. I'll be painting the ground the same color scheme. Hopefully it will look good.

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