Mandalorian costume WiPSubscribe
  1. Member Since
    Sep 2014
    Sep 27, 2014, 5:01 AM - Mandalorian costume WiP #1

    I'm writing this so I can keep my thoughts together. I'm going to try to keep all my costs documented. A quick background... I've been a Fett fan since I was a kid (40 now). I started to make a scratch costume many years a go, but did not have the money, skill, or ambition to see it through. This time I'll get it done. I am a also a gun nut. I have been teaching firearms for a little while and have some armorer experience. For job reasons, I have carried a gun to work for over 10 years now. Because of that, I want this build to have some real world logic to it. I know it's sci fi, but it's just the way my brain is wired anymore.

    This costume is for me. I don't have any current plans to join the 501st or Mandalore Mercs.

    Costs to date:

    Helmet-Rubie's one-piece Jango Fett $40.
    Jumpsuit-Blue nomex Flightsuit $6.
    Neck seal-
    Balaclava-USGI Green nomex hood $1.
    Chest Armor-
    Shoulder armor-
    Neck armor-
    Back armor-
    Waist armor-
    Cape/serape-USGI Shelter half $10.
    Wrist wraps-
    Sash or girth belt-OD 550 Cord $5.
    Leather belt-
    Leather holster-
    Leather pouches-
    Cargo pockets-
    Shin armor?-
    Elbow armor?-USGI elbow pads $3
    Boot spats-
    Long gun-Nerf Rayven and Hasbro E-33 $37.
    Pistol-Rubies Jango pistol $13
    Netting- $6
    Random Greebles-$2

    Trash can- $3
    Adhesive- $4
    Xacto- $2
    Velcro- $2
    Dremel wheels-$6

    Paints used:
    Rustoleum primer for plastics.
    Rustoleum camo flat black.
    Rustoleum camo brown.
    Rustoleum camo tan.
    Rustoleum flat brown.
    Rustoleum Aluminum.
    Testors dark green
    Testors metallic silver
    Testors flat black

    I am starting this build with the following concepts in mind. I am planning a modern Mandalore suit with a light/medium armor hybrid. I will be using similar Jango/Boba Fett patterns, decals and color schemes. I would like this to pass as an alternative suit that may have been in Boba Fett's closet. The suit will have its own history and damage, so I'll be starting with non-damaged armor. I would like to use dull earth tones for the colors. I want the suit to be modular. I will have a backpack eventually, possibly a jet pack, but I'll be starting out with no pack. I will be using an old west-style serape cape covering. The serape will be patterned after ones Clint Eastwood used as the man with no name.

    I plan to purchase cheap DIY items and put things together to test colors and fit. I'd like to follow it up with upgrades to more canon accurate pieces as money allows. What I replace will go toward a play suit for my son.

    I am planning to have a small arsenal of weapons. First weapon will be a long gun. The first thing I'll be doing is modifying a Nerf Rayven. It will have a barrel extension, scope, and laser. I have a sling in mind that will work similarly to one of the pre-production Boba Fett blasters. I'm also going to be adding LED read outs for the side. I'm hoping to make the LEDs and laser trigger-activated. I plan to make a dart or arrow attachment to go into the barrel.

    The build will include a Westar pistol for a sidearm. Probably going to get a Rubies pistol and paint it for now.

    I also have a Hasbro E-33 blaster I'll be repainting. Resin replacements may follow these.

    Nerf Rayven:
    I have sanded down all Nerf logos and safety markings. I have also sanded down the digital camo molded into the sides of the gun. I have began to prime the barrel extension (Rustoleum primer for plastics). I will be adding a medium gray next, then a metallic silver layer.

    Scored a used navy blue nomex flight suit for $6. Fit is perfect for me. I'm taking the pockets off and going to try to bleach it or hang it in the sun to lighten it up a bit.

    Bought a trash can from Walmart to test possible armor design ($2.97). Also purchased the LED car accent lights for the side of the Rayven ($12.97).

    I am hoping to find a used USGI shelter half this weekend for use as a serape.

    That is everything up to this point. More to follow...

    Last edited by Neeglik; Oct 22, 2014 at 3:52 PM. Reason: Updated cost list
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  3. Sep 27, 2014, 8:52 AM - #2

    Right on, man! Stoked to see what you come up with.
    Quote Quote Posted from Android app
  4. Peregrinus's Avatar
    Member Since
    Jun 2007
    Sep 27, 2014, 1:29 PM - Re: Mandalorian costume WiP #3

    What are you using for the extension? The Rayven has that convenient universal attachment lug at the muzzle, so you could use one of the barrel extensions from something like a Longstrike or Recon or Spectre. Personally,I think it looks best with the one from the Spectre. Here's a link to a blog of someone who did just that.

    You can also hunt for a simple woven poncho to use as a cape, and it would be accurate to the concept art.

    I'm presuming you are already aware of how far off the Rubies Westar and Hasbro EE-3 are. Unless you're really small, the underscaling of the EE-3 will be painfully visible. And I ended up using two of Rubies' Westars to combine into a single custom one (my build, so far, should you be curious), it was so unsalvagable as anything remotely close to movie-accurate. If you want something that looks like Jango's blaster, you can probably scavenge some bits off of it, and stick them onto a scratch-built base. There are darn good blueprints on here, and the barrel and barrel sleeve diameters are convenient plumbing/electrical pipe/tubing diameters. The last toy Star Wars weapons that were usably close to their prop analogues were the budget-model Luke and Vader "ForceFX" lightsabers, Hasbro's DH-17 dart shooter, and the old Kenner E-11 (that last admittedly with a lot of work).

  5. Member Since
    Sep 2014
    Sep 27, 2014, 2:40 PM - Re: Mandalorian costume WiP #4

    I'm using the Nerf Longstrike extension. My son and I have a Spectre, but do not have the extension for it. I'm going to keep an eye out for one though. Like I said above, I want this build to be modular in nature, so having a second extension is not a bad idea. My son hasn't picked out a nerf gun for us to mod for him yet. I painted a rough camo job on a Longshot last year, and he loved it. I kinda like the look of the Nerf Zombie Slingfire, but we haven't got one yet.

    I'm aware of the size difference in the Hasbro and Rubies toys. My boy will love the guns once I'm done experimenting with colors and weathering patterns. Eventually, I'll want to get the full size resin models. A lot of what I am going to be doing this year will be the version 1 or prototype, if you know what I mean. I do like how you're using two guns to build one good one!

  6. Peregrinus's Avatar
    Member Since
    Jun 2007
    Sep 27, 2014, 7:30 PM - Re: Mandalorian costume WiP #5

    There are a couple Spectre barrel extension on the 'Bay right now. $20/free shipping. I have one I'm not terribly attached to that I'd be willing to part with for far less than that. PM if interested and we can sort out details.

    I'm a big fan of both modularity and test-runs/prototyping. My initial Mando interest was to make a Clone Wars era Fenn Shysa (color-corrected from Marvel's atrocious coloration technology/technique of the early '80s). Metal armor. Lots of "play features", i.e. working/moving bits. While working on that I got fired up to do a custom as well. Both of those, however, are going to be several years yet until they are fully realized. So, partially to familiarize myself with some elements that I will be making out of metal further on that I'm either scratch-building out of sintra or got the vac-formed versions of to check fit and use for reference. I'm also modding a Hasbro Boba Fett helmet toy just to see how decent I can make it look. So I decided to put them to use, along with "waster" parts I got from the guy who did the initial cutting and rough-forming of my torso plates (collar and cod were just going to get tossed). Those, plus pieces from those two main costumes that I do have sorted out, and a couple pieces I'm making just for this one, have all become what I call my "v0.5" kit. That's what the other links in my sig, over in that Westar thread, lead to.

  7. Member Since
    Sep 2014
    Oct 1, 2014, 11:00 AM - Re: Mandalorian costume WiP #6

    I picked up a shelter half and have made a serape out of it. It needs weathering, and maybe a bit more damage, but I like the look of it so far.

    I saw some leather straps at the surplus store that I'll probably go back and get. Very interesting hardware and hooks. I'm not sure what they came from but it looks ideal for either a sling or belt/holster parts. *edited to add that I got these. They are part of the shoulder straps from a European military pack. I'm 99% sure I'll be using it for the sling harness for the Rayven.

    I have removed most of the pockets from my flight suit. I plan to replace the remaining zippers with Velcro.

    I've cut chest armor from the trash can I purchased. I went with the child size for test purposes. It looks ok for my boy, but I think I'd prefer something thicker for me.

    Hopefully, I'll have some stuff completed to where I can start taking pics soon. More to follow...
    Last edited by Neeglik; Oct 2, 2014 at 6:34 AM.
  8. Member Since
    Sep 2014
    Oct 10, 2014, 7:27 PM - Re: Mandalorian costume WiP #7

    I have removed all but one of the pockets on the flight suit. I'm probably going to remove the collar also. I've given it a pretty heavy dose of overspray with Rustoleum camo tan, brown, and black. The original dark blue was just too dark for me.

    The serape is done for now. I added some graphics with the Rustoleum camo black. Nothing much, but I wanted more than just OD green. I weathered it the same way as the flight suit.

    My barrel extension is almost done. I'll be gluing on a couple things, then touch ups on the paint and a dull coat to finish it off. The Rayven is coming along, but still need to figure out the wiring for the electronics.

    I cut up some OD 550 cord for use as a girth belt. I wanted to do something different than the standard maroon colored belt from Boba Fett.

    I plan to go back to the surplus store. I have my eye on an air crew rig they have at a good price. It has at least 4 cobra buckles on it. I think they would make a better futuristic look than plastic fastex for belts, vest, pack harness, etc.

    I am contemplating using an USGI OD sleep shirt for my vest. I'm gonna look at them a little closer and see if it will work or not.
  9. Member Since
    Sep 2014
    Oct 13, 2014, 7:55 AM - Re: Mandalorian costume WiP #8

    Scored a 1 piece rubies Jango Fett helmet for $40. Hopefully it will arrive this week and be one of the better examples to come from Rubies. Either way, I'll at least get to experiment with my color pattern and modding of a helmet.

    I hope to start sewing my 550 cord together for the girth belt this week. Not sure how that's gonna turn out, but we'll see...

    WiP pics...

    Front of flight suit and serape so far.


    Barrel extension so far, along with leather for sling.
    Last edited by Neeglik; Oct 13, 2014 at 8:16 AM.
  10. Member Since
    Sep 2014
    Oct 22, 2014, 10:43 PM - Re: Mandalorian costume WiP #9

    Rubies Jango Fett 1 piece arrived. Overall good condition for what it is. Some warping. I applied some heat and got some of the overly oval shape out of it. I applied some USGI helmet pads to the inside so it doesn't spin around on my head. It is short, my chin is visible. Again, this will be a temporary/training helmet that will ultimately go to my 6 year old. I wanted more Boba Fett colors, so I went with a green and red colors. I plan to cut out the visor and add a full size one. Ultimately it doesn't look too bad, but I definintely look forward to getting a better bucket.

    Grabbed a Rubies Jango pistol. I plan to paint it silver and/or black. I'll probably glue or otherwise reinforce it. It's pretty cheap.

    Picked up some random lawn tool stuff for adding to the costume or possibly to my future backpack.

    Also picked up some better needle and thread for the paracord girth belt that I haven't started on yet.

    Pics to follow.
  11. Member Since
    Nov 2014
    Dec 8, 2014, 11:25 AM - Re: Mandalorian costume WiP #10

    Like the green.
  12. Member Since
    Sep 2014
    Dec 8, 2014, 7:20 PM - Re: Mandalorian costume WiP #11

    Haven't updated in a while.

    Jumpsuit collar and all pockets are removed. Need to re-sew some seams.

    Nerf Rayven got hit with the dremel. The removal of some of the stock and thumbhole grip, plus the addition of a Crossman scope and laser sight really help de-Nerf the look. Gonna find some bondo or body filler to finish it up. Here's a pic with some of the cuts made and parts laid next to each other.

    I finished sewing together my paracord today. I need to figure out what straps and buckles I want to use to finish the girth belt.

    I ordered a pair of Boba Fett cargo pouches. They should arrive soon.

    I wore my Rubies helmet and onesie jumpsuit and grabbed my Hasbro Boba Fett blaster for my Halloween outing. Pretty lame setup, but I did get a lot of compliments. Everybody loves the Fett! I told them to just wait and see what I do for next year!!
  13. Member Since
    Sep 2014
    Mar 12, 2015, 4:50 PM - Re: Mandalorian costume WiP #12

    Haven't done much lately. I did finally get my cargo pouches. The first set came as two of one side. One of them has some crappy stitching too. I notified my source and they sent two of the other side, giving me two full sets. If anyone can use a set of ESB belt mounted cargo pouches, drop me a line....

    Lately, I've seen a guy who took a modern US military approach. I'll see if I can link his pics. I think im going to steal some of his ideas. Mainly thinking about linking the armor with buckles, and using some night vision and light attachments from the military for the helmet.
  14. Member Since
    Sep 2014
    May 10, 2015, 9:59 AM - Re: Mandalorian costume WiP #13

    Still haven't done much. Girth belt and blaster are still sitting unfinished, although I did free up the area around the rear of the pistol grip and am happy with the result.

    I have been collecting parts. I have a new visor on the way for the Rubies helmet. I also have airsoft ARC accessory rails with Princeton Tec MPLS led lights and side armor for eventual helmet mods. I ordered boot spats. Next looking to get belt and belt pouches, gauntlets, vest and chest armor.

    This should give me a decent lightweight armor variation in time for Halloween and possible wear to The Force Awakens viewings. I'll add and improve during 2016.

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