Bo Katan Bo Katan Journey Begun

warhawk50

Jr Hunter
Here are some pics of a recently arrived Bo Katan helmet (woo hoo!). My kid was excited. I went ahead and did a quick trim of the visor area (thank you dremel). It will need a tad more sanding/trimming in the inside but I think it is a mighty fine helmet. I am thinking for the rest of the build to use a unitard for the main body, then probably a heavy cotton for the vest as suggested in a previous post. I am assuming 3mm sintra is the way to go for the armor plates. My daughter is a tween so I am thinking of doing a standard mando DW pattern for the armor as opposed to giving cups. I know Bo Katan has cups, but then she is also a grown woman (am I too worried about this?). So I guess instead of a Bo Katan she'll be her lesser known little sister, Go Katan (or would No-Go Katan be more appropriate?) :) Wish me luck!

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Here are couple of pictures of the helmet I am working on. Tony and I talked color and if I recall we thought maybe try Krylon Ocean Blue. Here is the fresh coat.

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Paint and visor complete!
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Her response to the helmet?

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Thanks to Tony for helping me with the visor install.
 
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On the pne I painted up for me, I actually used a couple of really short screws from the inside of the helmet into the earcap portion of the stalk. Youll need to predrill the holes and use a drop or two of loctite.
 
Well, here is a picture of a unitard I ordered from a local dance shop. It is a Bal Tog mock turtle neck in "gasoline grey". I think it is pretty darn close in color. Its a tad darker in the pic than it really is. For a better description of the color, go to Bal Togs Supplex/Lycra Color Chart

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Well, Tony and I finally bit the bullett and dove in on trying to make some body armor for our younglings. We are lucky they are similar in size. I was able to get a hold of sintra from Meyers Plastics. We opted for 3mm. It comes in 48"x96" sheets at less that $30 per sheet. They also cut them to size for me. I had no idea how much we would need so I opted for two sheets which I had them cut into quarters so it could fit in my car. Based on the progress we are making so far, we are going to have a lot of sintra left over.

First we went for the shoulder bells. To help with the curve we used a small plastic dish to trace. This is the the first time either of us had worked with this material so this is a learn as you go project. Tin snips we found if you weren't too careful would easily split/crack/fracture the plastic. A dremel or jig saw is highly recommended.
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To get the curve/flare we used a standard spray paint can along with a heat gun. The sintra responded beautifully to the heat and cooled quickly. We think the shoulders turned out GEFG (good enough for government) :)
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From there we moved on to the thigh plates. Here we used the templates generated by DOD and formed them around standard gallon paint cans.
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We were starting on the holster parts before we had to call it a night. Hope to make more progress soon!
 
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More pics from the build Tony and I have been working on. We did the holster, chest, neck, abdomen, and knees. The chest was difficult and may require further fine tuning.

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