I have been working on a Boushh costume for my wife along with a Boba Fett for myself. Her costume is going to be completed before mine. I started with a pepakura file for the helmet from Skip. The helmet was reinforced using architectural cardboard & smooth cast as well as filler.
The armor, tanks (back pack), boot disks, bandolier, & chest piece were all drawn up in cad & I created a 3D file and did this in pepakura as well. I used multiple layers of the same architectural cardboard & some fiberglass mesh & layers of smooth cast for the construction. I found this made for a sturdy light weight construction. I did things as a laminate very similar to plywood construction. I scratch built all the detail pieces as well as did all of the painting myself. I have tried various things during this process and have learned lots. I already have plans to improve things that I did early on.
The staff was built based on reference photos & scaling the hasbro & sideshow 12" Boushh figure staff.
The thermal detonator is the Hot Potato game that was offered during the Star Wars Weekends at Disney. I just did a repaint on it. I thought this was a good alternative to making one.
My wife is working on the soft parts while I am doing all the fab work.
The goal is to have this completed by Chicago Comic Con.