I bought some Evolution stuff and was and happy, so now I'm making my own set along with my girlfriend's so we can troop together. I bought some 3mm sintra, but decided that forming it wasn't as appealing for my first scratch set, so I chose the trash can method.
As of today, shoulder bells are cut out (Dremel style - I cannot say it enough, this is the way to go. Tin snips just don't cut it, no pun intended). Our other plates, minus the back, are traced out and waiting on me to go on the back porch in a hour to cut out. I think I should also mention for all you Mando couples/families - you can get two full sets off of each can (i.e. two sets of shoulder bells off the small can & two sets of frontal chest/neck armor off the big can). I am going to experiment with trying to get our kneepads off of the remaining chunks of can.
Helmets are still in paper form. I am fiberglassing my dome today and cutting a 1mm sheet of sintra for the barrel. If I cannot get a good grip on this bucket my Monday, I might just suck up the cost and buy ours. The only thing I am worried about is that she is very petite (4-11 & 115lbs). I was very humorous to see her plates stenciled out next to mine (I'm almost 6 ft & 200). Speaking of size, Its very strange to see the Evolution armor next to the WOF templated armor...Evo is so much smaller.
I had bought a cucblack vest (which is alittle snug for my tastes) so I am not gonna use it for my custom Mando. I have chosen to go a different direction for that & I will have pictures posted later of it. I am lucky and have a military surplus store right down the road, so I got a nice blue jumpsuit for 11 bucks. A side note, they have tons of nicely real world weather shelter halves for those of you wanting Boba style capes, just lemme know if you need one.
All & all, I feel real good about this build so far. Since it's a custom Mando, I feel so much less intimidated scratch building it since I do not have to meet the exacting standards of the community by building a Boba. Pictures to follow this evening, but other than that... Questions, comments & tips?