need help

In my opinion for $150 and being 5'1", this is very doable. First try to find a plastic shop nearby selling sintra (foam PVC). Should be around $20 for a 3x3 sheet in 3mm (1.8 inch). If you want a full Jango style set, buy a 4x8 for $40. Ebay will also sell these, as will my favorite store, TAP Plastic. Really depends on where you live, but most places ship. In my next reply I will have all the links. Download WOF templates from here and print them out, preferably on cardstock. Cut them out and place them on your body to make sure they fit well. Try to have a thumbs' width between plates. Remember the belly plate rides higher and your navel should be exposed. Place your collar first, then chest, then diamond, then belly. Lay the templates on the sintra, trace the shape, then using a box cutter ($5 - Walmart, Lowes, etc) carefully cut the shapes out. Cut a couple of times on the line as opposed to trying to cut through in one swipe. If you have a scroll saw or band saw, those work wonders, but not everyone has power tools. Then get some sand paper and clean up the edges. Hopefully you can get your hands on a dremel or cheap rotary power tool ($20 from Harbor Freight online) to round your edges. Once that's done, turn on your oven to 175 degrees and get a pair of gloves. Turn the kitchen faucet on cold then place an armor piece in the oven. Watch it carefully and after a minute or two, the plastic will get floppy. Once it gets slightly floppy (not totally), take it out and place it on your body. Form it to your shape an hold it for 30-60 seconds. It will retain that shape for the most part, then quickly place it under the cold water to lock the shape in. Once they are all formed, base paint it with silver. Draw on battle damage with mustard, then paint on your main colors. Once the paint dries, wash off the mustard to expose the "raw metal"

Go to a military surplus store or look on ebay for any coverall, flightsuit or similar style item for your flightsuit. Also, solid color BDU or cargo pants can work, with matching color long sleeve shirt. Look for a neck gaitor or similar style neck warming item for your neck seal. Walmart sells great black mechanics gloves for cheap also. While your at the surplus store, look for used military boots. Then hit up a Salvation Army for a vest or long sleeve item you can cut sleeve off for your vest.

For the helmet, your in luck and can buy a Jango 2 piece for $30. You JB Weld or whatever it together, putty the seam, then buy a fiberglass kit from Walmart for $10 to coat the INSIDE of the helmet. Now you will have a nice solid bucket. Go to a safety store and pick up a faceshield for your visor $4 and some tint from most any store like Walmart, Fred Meyers or whatever. Also Autozone.
 
Gymbeau2000 You've given me soom great direction to follow. Tomorrow I start my build with visions of Mercs and Blasters in my head! You Mandalorian Mercs are my inspiration. Some day I hope to meet you guys some where and buy you all a beer!!
 
Your welcome djgus! Wherever you are, there is likely a Mercs clan (group). PM me if you need more help or info.

Cody, if your budget is down to $50, you may want to consider just doing more research & finding of items for now until you can save more cash. The figures and info I gave you are for bargain basement stuff. Most of us that have very elaborate gear or those of us who upgrade will end up spending a couple of hundred just on a raw helmet! If you have done any research around here, you will know costuming is an expensive hobby. But don't get discouraged, just buy like your helmet, putty, glue, paint and the fiberglass kit (that would be roughly $50). You can then have your completed bucket. In the mean time, dig around the local surplus stores and goodwill type stores to find things you may like. Try on some flightsuits and find your size so if you find a good deal on Ebay you know what to get. Print out your templates and size them. If you have a printer, you likely already have paper. Go to the Mercs site and use the MandoMaker program to layout your colors and design of how you want your Mando to roughly look.
 
There's two methods, boiling water or the oven. Just remember to wear heat proofed gloves when bending. Having a bucket of cold water at hand once you have properly bent the plate will help set the plate quickly.

It may take a few goes to get the bends right and, as is the mantra of building armour, taking your time will prevent you making serious mistakes.

May I advise: DO NOT USE THE OVEN FOR MORE THAN A FEW MINUTES @ A TIME!!! there have been issues with injuries. If you do use the oven, open all the windows and wear a vapor mask.
I would advise using a heat gun.
 
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