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  1. Refestus's Avatar
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    Sep 2010
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    Oct 3, 2010, 3:15 PM - First custom Mandalorian costume (Pic intensive) #1

    Hey all,
    I made an account not too long ago on this site and was really inspired by the immense creativity of the members here. You guys are awesome at what you do.
    So after seeing all the costumes that you've made on here I decided to make one of my own and I'd like to share my progress with all of you. With my build I was going for something cheap and quick, but still good looking. I finished all the armor in about a week/week and a half for around $100.
    Click image for larger version. 

Name:	Trashcan Armor.JPG 
Views:	6089 
Size:	2.13 MB 
ID:	47024
    So here is the majority of my armor stenciled out on cheap trash cans, ready to be cut out. I used WOF's Jango templates. I'm now a huge fan of WOF. How he has the time to create such awesome templates for all of us to use I'll never know.
    Click image for larger version. 

Name:	Vest back.JPG 
Views:	522 
Size:	2.47 MB 
ID:	47025
    One of the first things I did was create a vest. This one is just a quick temporary one, I'm planning on upgrading soon. Here is a shot of the back. Please excuse the lack of craftsmanship on this, I did it very quickly without much accuracy...
    I used a t-shirt for a basic pattern. To create a snug fit I sewed a stretch fabric into the sides and shoulders. Like I said, this is just temporary, I'm a little embarrassed about how janky the overall product is...
    Click image for larger version. 

Name:	Vest front.JPG 
Views:	375 
Size:	2.44 MB 
ID:	47026
    This is a shot of the front. The armor attaches to the vest via velcro for now although I find that this method is kind of hit or miss in terms of the strength of the hold.
    Click image for larger version. 

Name:	Armor cut out.JPG 
Views:	676 
Size:	2.31 MB 
ID:	47032
    This is my armor all cut out and sanded, ready for painting. This was probably the most time intensive portion of the build (not to mention the messiest). My garage is currently covered with about a ton of plastic dust that my tarp didn't catch. I used a dremel tool to cut out and sand the armor. The trash cans worked brilliantly in terms of the fit of the armor. Where the fit wasn't quite right (such as the legs and back) I used a heat gun to bend the armor. I'm still having problems with that darn back plate.
    Click image for larger version. 

Name:	Helmet just opened.JPG 
Views:	1033 
Size:	2.15 MB 
ID:	47031
    For my helmet I used a Rubies two piece. Here's my helmet right out of the box. It was a little more flimsy than I expected, but what can you do?
    Click image for larger version. 

Name:	Helmet with plastic fill.JPG 
Views:	402 
Size:	2.22 MB 
ID:	47028
    To fill the gap in the helmet I originally used a modelling putty called green stuff (all you 40k players out there will know what I'm talking about), but that didn't quite do the trick. So after that failed I did a little experimenting and found that a good method was to melt the plastic trashcan scraps into the gap with the heat gun. It's not as pretty as some of the other buckets I've seen on here, but it provides as strong a bond as I require.
    Click image for larger version. 

Name:	Armor base coat silver.JPG 
Views:	476 
Size:	2.16 MB 
ID:	47029
    Here's my armor base coated in silver. Before the silver I did an original coat of black so that the silver would adhere more readily. I almost thought about leaving it in this state and making myself a suit of Jango armor!
    Click image for larger version. 

Name:	Armor Painted without stripe.JPG 
Views:	570 
Size:	2.28 MB 
ID:	47027
    Now here's my armor painted, almost ready to go. I sprayed it with a metallic paint that has a hammered texture as I wanted my armor to look old and weathered. I used the mustard method for exposing the silver base coat to create a weathered look.
    Click image for larger version. 

Name:	Armor Painted with stripe.JPG 
Views:	2049 
Size:	2.24 MB 
ID:	47030
    And here's my armor all painted up with my awesome orange stripe and orange kill marks. I used latex paint and sponged it onto the armor in 3 coats with a piece of foam scrap.

    So that's my armor so far! I'd love to hear some feedback or suggestions from all of you. I'll post updates as I can. I have since created a sash, cape and handwrap, installed a new visor, and touched up the painting.
    Last edited by Fett 4 Real; Jan 14, 2013 at 8:18 PM.
  2. Evilhemmes's Avatar
    Member Since
    Aug 2010
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    211
    Oct 3, 2010, 4:04 PM - Re: First custom Mandalorian costume (Pic intensive) #2

    nice love the GT stripe.
    have to see it on you, post pics when u get your game on.
    Last edited by Evilhemmes; Oct 9, 2010 at 5:53 PM.
  3. Member Since
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    Oct 3, 2010, 4:14 PM - Re: First custom Mandalorian costume (Pic intensive) #3

    xD i would have rather gone with red then orange but otherwise its beautiful
  4. Saz.'s Avatar
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    Oct 5, 2010, 7:13 AM - Re: First custom Mandalorian costume (Pic intensive) #4

    Actually I think that orange is the new red when it comes to Mandos... there has always been a lot of red and black with paint jobs, usually because they go so well together.

    I like that paint job, it's individual and works well with the grey.
  5. Member Since
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    Oct 5, 2010, 8:20 AM - Re: First custom Mandalorian costume (Pic intensive) #5

    Quote Saz. said: View Post
    Actually I think that orange is the new red when it comes to Mandos... there has always been a lot of red and black with paint jobs, usually because they go so well together.

    I like that paint job, it's individual and works well with the grey.
    as far as i'm conserned styles and tastes shouldn't be discussed because some people like thing different then other,like for example most people like their armor nice and weather and true to the very unrealistic done comic books and movie while i prefer my armor with no weathering mainly because i find it unrealistic,or how some people like to eat cereal for breakfast while others prefer a home cooked meal with no cereal at all
  6. Refestus's Avatar
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    Sep 2010
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    Oct 6, 2010, 8:04 PM - Re: First custom Mandalorian costume (Pic intensive) #6

    Thanks guys! Yeah I just like orange so I wanted to work it in somehow. I also saw a helmet that had orange kill marks where I have mine and I really liked the look of it. I wish I could find the picture so I could give credit but I can't find it.
  7. Refestus's Avatar
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    Oct 11, 2010, 9:03 PM - Re: First custom Mandalorian costume (Pic intensive) #7

    Just a quick update. I touched up the painting and added some details:

    Click image for larger version. 

Name:	DSCN1154.JPG 
Views:	266 
Size:	2.05 MB 
ID:	47291
    Here's my left chest plate with some Mandalorian script.

    Click image for larger version. 

Name:	DSCN1153.JPG 
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ID:	47292
    Some more script near the vent.

    Click image for larger version. 

Name:	DSCN1158.JPG 
Views:	616 
Size:	2.34 MB 
ID:	47294
    The obligatory Mando badge.

    Hopefully I can get pics of the whole costume up soon!
    Edit: with me in it of course.
  8. Refestus's Avatar
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    Sep 2010
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    Oct 11, 2010, 10:04 PM - Re: First custom Mandalorian costume (Pic intensive) #8

    I'm a man of my word, here are pictures of the completed costume (minus the left thigh armor due to malfunction)

    Click image for larger version. 

Name:	Mando Front.JPG 
Views:	797 
Size:	2.33 MB 
ID:	47302

    Click image for larger version. 

Name:	Mando Left.JPG 
Views:	550 
Size:	2.33 MB 
ID:	47300

    Click image for larger version. 

Name:	Mando Back.JPG 
Views:	557 
Size:	2.10 MB 
ID:	47303

    Click image for larger version. 

Name:	Mando Right.JPG 
Views:	584 
Size:	2.34 MB 
ID:	47304

    Click image for larger version. 

Name:	Mando 1.JPG 
Views:	501 
Size:	2.21 MB 
ID:	47299

    Click image for larger version. 

Name:	Mando 2.JPG 
Views:	368 
Size:	2.34 MB 
ID:	47301
  9. Ordeyn's Avatar
    Member Since
    Jan 2009
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    746
    Oct 11, 2010, 10:33 PM - Re: First custom Mandalorian costume (Pic intensive) #9

    This is a wonderful kit for a first timer. I very much like the combination of orange and grey together, especially with the long, straight pattern you've partnered with the pair or colors. One question though: is you neck really that long or am I crazy?
  10. Refestus's Avatar
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    Oct 12, 2010, 1:18 AM - Re: First custom Mandalorian costume (Pic intensive) #10

    Quote Ordeyn said: View Post
    This is a wonderful kit for a first timer. I very much like the combination of orange and grey together, especially with the long, straight pattern you've partnered with the pair or colors. One question though: is you neck really that long or am I crazy?
    Thank you, it still needs a few tweaks, but it'll do for now.

    Yeah, picked that up from the gene pool apparently. I can see really really well over people at events though so it comes in handy.
  11. Member Since
    May 2010
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    168
    Oct 12, 2010, 5:02 AM - Re: First custom Mandalorian costume (Pic intensive) #11

    Quote Refestus said: View Post
    Yeah, picked that up from the gene pool apparently. I can see really really well over people at events though so it comes in handy.
    xD bet it would be a disadvantage in a battle against a jedi lmao
  12. Member Since
    Oct 2010
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    Oct 13, 2010, 3:21 AM - Re: First custom Mandalorian costume (Pic intensive) #12

    I'm so in love with this paint job. I'm going to use something like it for mine (same orange racing stripe, but using a lighter grey. I'm also going to do a custom helmet inspired by one of the guys on the forum I forget the post -- i only saw it in passing and loved it.)

    Sorta a sand mando (I'm a TD in the 501st so I'm sorta partial to the dryer climates.)

    Here's the mockup I did.


    I probably won't roll with holsters as well. Going to carry an assault rifle I think.
    Last edited by MiDri; Oct 13, 2010 at 3:31 AM.
  13. Refestus's Avatar
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    Oct 13, 2010, 3:31 PM - Re: First custom Mandalorian costume (Pic intensive) #13

    Quote 72555 said: View Post
    xD bet it would be a disadvantage in a battle against a jedi lmao
    Yeah, on the back of my neck seal I'll stitch a dotted line and the words "Cut Here"

    Quote MiDri said: View Post
    Here's the mockup I did.
    That's rad, I especially love the helmet! How are you going to do the gold visor?
  14. Member Since
    May 2010
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    Oct 13, 2010, 4:17 PM - Re: First custom Mandalorian costume (Pic intensive) #14

    Quote MiDri said: View Post
    Here's the mockup I did.
    **** if only it was green with red and more boba style i'd be drooling all over it...but its cool this way too...i just got a natural affinity to green and red combination,don't know why,just do,think its got something to do with my last job being in the army and my fave collor being red?

    Quote Refestus said: View Post
    Yeah, on the back of my neck seal I'll stitch a dotted line and the words "Cut Here"
    Lmao and the line could be orange too so it fit with the armor XD
  15. Member Since
    Oct 2010
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    Oct 13, 2010, 4:37 PM - Re: First custom Mandalorian costume (Pic intensive) #15

    Quote Refestus said: View Post
    Yeah, on the back of my neck seal I'll stitch a dotted line and the words "Cut Here"



    That's rad, I especially love the helmet! How are you going to do the gold visor?
    Mirror finished acrylic, they're a bit hard to find but a lot of people have them for Commander Gree outfits and the like. (not normally gold, but it is around) same stuff they make mirror sunglasses out of.
  16. Refestus's Avatar
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    Sep 2010
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    Oct 13, 2010, 10:15 PM - Re: First custom Mandalorian costume (Pic intensive) #16

    Update:
    As many of you may have noticed I was using a cheap Rubies holster set. I don't have too many complaints about the pistols but the holsters were absolute trash. Hell even I could build a better set! So I did.

    I had some extra pleather around so I turned it into this:
    Click image for larger version. 

Name:	Harness right.JPG 
Views:	377 
Size:	2.29 MB 
ID:	47327
    Click image for larger version. 

Name:	Harness front.JPG 
Views:	391 
Size:	2.33 MB 
ID:	47328
    Click image for larger version. 

Name:	Harness left.JPG 
Views:	208 
Size:	2.32 MB 
ID:	47329

    I also repainted the pistols. I spray painted the grips black with some weathering. It goes with my armor better, but they're still Jango's pistols (which I like).
  17. Member Since
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    Oct 14, 2010, 12:02 AM - Re: First custom Mandalorian costume (Pic intensive) #17

    You have a template laying around? I might make some to try them out.
  18. Refestus's Avatar
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    Sep 2010
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    Oct 14, 2010, 1:51 AM - Re: First custom Mandalorian costume (Pic intensive) #18

    I don't have templates unfortunately as I was using the Rubies' holsters as a guide, but it isn't too hard to make your own. I'll try to explain my process:
    1.First I cut out my holsters.
    The holster backing is a kind of triangle/rhombus that is 9 inches on one long end and 7.5 inches on the other long end, 2.5 inches wide at the top and 1.5 inches wide at the bottom. This shows the basic shape:
    Click image for larger version. 

Name:	Holster backing detail.jpg 
Views:	242 
Size:	1.23 MB 
ID:	47341
    This is the left holster.
    *Note: For the right holster, just reverse the pattern.
    The actual holster part is just another rhombus that is 9 inches on one long end and 7.5 inches on the other long end, 5 inches wide at the top and 4.5 inches wide at the bottom. Here again is the left holster:
    Click image for larger version. 

Name:	Holster detail.jpg 
Views:	179 
Size:	1.22 MB 
ID:	47340
    *For the right, again, reverse the pattern.
    2. Next, I cut my pleather into strips that would serve as the main belt, front and back straps (the ones that hold the holster to the belt itself), thigh straps (that wrap around the thigh armor, securing the holster to the leg) and that little strip that goes through the metal piece on the front.
    The front straps are 10.5 inches long and 1.5 inches wide. One end is looped around a D ring like so:
    Click image for larger version. 

Name:	D ring attachment.JPG 
Views:	227 
Size:	2.25 MB 
ID:	47342
    and about 2.5 inches of the other end is glued to the backing of the holster like so:
    Click image for larger version. 

Name:	Holster backing strap attachment.JPG 
Views:	178 
Size:	2.35 MB 
ID:	47344
    Next we do the back straps. These are 21 inches long and 1.5 inches wide. loop them so that their edges touch and glue it onto the back of the holster like so:
    Click image for larger version. 

Name:	Holster backing strap attachment.JPG 
Views:	178 
Size:	2.35 MB 
ID:	47344
    The loop is what the main belt goes through:
    Click image for larger version. 

Name:	Back strap loop.JPG 
Views:	144 
Size:	2.37 MB 
ID:	47343
    The little strip that fits through the metal piece:
    Click image for larger version. 

Name:	Metal detail.jpg 
Views:	191 
Size:	1.33 MB 
ID:	47339
    is 6 inches long, 1 inch wide. and is looped around the D ring on each end like so:
    Click image for larger version. 

Name:	D ring attachment.JPG 
Views:	227 
Size:	2.25 MB 
ID:	47342
    Now comes the main belt. My belt is 37 inches long, 1.5-2inches wide. However, I'm thin (32 inch waist) so you can adjust this as necessary.
    All the straps (waist, and thigh) attach with velcro. All assembly was done with hot glue.
    Feel free to ask any questions if something wasn't clear and I'll try to clear it up (This has been my first tutorial). Sorry for the lack of templates, I've never made a template and currently don't have a scanner or anything even if I wanted to make one.

    Edit: I almost forgot to say that these holsters are for the Rubies Jango blasters. For real replica blasters, add an extra 1.5-2 inches to the holster length. Don't change the strap dimensions though!
  19. Member Since
    Sep 2009
    Posts
    118
    Oct 14, 2010, 8:52 PM - Re: First custom Mandalorian costume (Pic intensive) #19

    Good looking Mando & holsters. The color combo is very slick! I like the Starkiller-ish vibe you have going too.
  20. Member Since
    Aug 2009
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    144
    Oct 14, 2010, 10:57 PM - Re: First custom Mandalorian costume (Pic intensive) #20

    looks awesome
  21. Refestus's Avatar
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    Nov 9, 2012, 12:38 PM - Re: First custom Mandalorian costume (Pic intensive) #21

    Necroposting for a good cause, I assure you.
    I just came back to this thread and boy does it bring up some memories... Anyway, I think it would be interesting and informative to show you all where this kit has progressed from where I left it off here. What you see in the previous posts is obviously a Halloween costume. Not approvable by any club ever. Forever.
    BUT, I've managed to take my costume from that stage to where it stands today.


    More pictures and documentation of the evolution of the costume and other pieces on my Facebook HERE.
    Last edited by Refestus; Nov 13, 2012 at 2:33 PM.
  22. Syper's Avatar
    Member Since
    Oct 2008
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    901
    Nov 13, 2012, 2:31 PM - Re: First custom Mandalorian costume (Pic intensive) #22

    Great Work Peepz!!! I have been collecting **** for my custom Mando for years...Its time
  23. Member Since
    Jan 2013
    Posts
    9
    Jan 4, 2013, 9:29 PM - Re: First custom Mandalorian costume (Pic intensive) #23

    Is that updated current pic still the original trash can armor you created to start this thread??
  24. Refestus's Avatar
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    Jan 9, 2013, 2:44 AM - Re: First custom Mandalorian costume (Pic intensive) #24

    Thanks Syper. Yeah you're going the right route by doing it right the first time!

    FrancT: No, the trash can armor was retired. I upgraded to sintra plates.
  25. Jan 9, 2013, 8:06 AM - Re: First custom Mandalorian costume (Pic intensive) #25

    Hell yeah! Love the gun and the pose in the picture. Very great costume!

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