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!