ROTJ SE Scratch Build WIP - Advice Welcome

mcfarlj3 · Sep 15, 2014

I can't decide how to attach the shoulder bells. I'm planning on using grommets, but don't want to place the grommet over the stitching on the ribs of the sleeve. Should I put the grommet in first to avoid the ribbing, then place the shoulder bell on the sleeve and make a mark on the shoulder bell through the grommet?

SPY007 · Sep 15, 2014

Very nice work. If you are scratch building a helmet, I recommended Rafel Fett's templates. They are more accurate than WOF's Girth belts aren't that expensive, look for morhair. You can buy cheap hair extensions at Sally Beauty supply for Wookie braids.

mcfarlj3 · Sep 16, 2014

Thanks Spy007. After painting my armor, the helmet is next. I've been mentally prepping for the helmet and planned on using Rafel Fett's templates. A friend of mine has horses so we'll see if I can get some horse hair for the Wookie braids. Also, after placing the bolts I'm beginning to wonder if you could cut off the head of the bolt and glue/bondo the bolt threads to the armor and then be able to pull the armor as close as possible to the vest. The bolt head wouldn't get in the way and leave a gap. But that's a project for the future. I guess a Fett is never really "finished".

animattor · Sep 16, 2014

This build is looking very solid man. Your knees look very good keep it up!

mcfarlj3 · Sep 17, 2014

I plan on using rattlecans for my paint job. Are Valspar and Krylon really as bad as people say? I know Rustoleum is good, but it's also more expensive.

Armydad · Sep 17, 2014

Velcro is another option for attaching the shoulder bells, that way at least you wont compromise the stitching on the panels. The shoulders dont usually have very much movement to deal with, I dont think anyone really does full out running and gunning in costume to warrant bolting them down. Either way they'll hold well enough.

mcfarlj3 · Sep 20, 2014

Thanks for the insight Armydad. I think I'll use Velcro on the shoulder bells. Updates on those soon hopefully, but right now I've been starting to paint. Initially, I though Rust-oleum was a lot more expensive because Joanns was selling it for $8.00 a can. I went to Home Depot and they had tons of colors for $3.44 a can. Needless to say I stocked up on paint. This isn't all the colors I plan on using, but it's a start.

First, I started with a coat of gray.

Then a coat of metallic silver.

I've been using a small piece of scrap sintra to test every coat before doing the armor. While I'm painting I'm working on the last few details of other pieces. I realize I probably won't have time for the jetpack by the end of Oct, but it's not Boba Fett without the helmet and the gauntlets. I'll be working pretty hard for the next month to get everything done.

mcfarlj3 · Sep 23, 2014

I've been doing a lot of painting the past few days. First, though I had to prep the cod piece with bondo and sand it smooth. There are a few rough spots, but it turned out better than expected.

All the armor got a coat of grey primer and then metallic silver. Next I used masking fluid to mask off the appropriate areas using Raf's stencils as a guide.

Then I masked off the areas that need to stay yellow and put on a coat of Spruce green (the lighter green). More masking, then Hunt Club green. Here's a picture of my progress so far. (The knees are on hold for now)

A little more masking, another coat of paint, and it will be ready for weathering. I'm still brainstorming the best way to do the chest and shoulder decals.

mcfarlj3 · Sep 23, 2014

Peeling off the masking fluid is pretty exciting. Here's what I've got so far. The yellow is a little overwhelming to my eyes, but I think the weathering and black misting on top will tone it down.

SPY007 · Sep 26, 2014

Once a again, very nice work. The advantage of Krylon is the faster drying time, But I do agree the 2 Rustolium greens are more accurate. I chose velcro for may armor.

xarbiterx · Sep 26, 2014

This looks incredible man. Super impressed. Keep this up. Excited to see the final product.

mcfarlj3 · Sep 27, 2014

Thanks for all the encouraging feedback! I'm really enjoying painting the armor. It's been challenging at times, but good. Here are a few pictures of the armor so far. I did a little weathering. Do you think I need more? These were taken outside not in direct sunlight. The other pieces are in the process of getting the decals.

mcfarlj3 · Oct 2, 2014

All of my free time has been spent working on various aspects of the costume. I had to redo the ammo pouches because the hot glue didn't hold. I used a stronger glue and a staple gun in inconspicuous places. It's working a lot better. I also attached the shoulder bells using velcro as suggested by Armydad (thanks!). The helmet has been my main focus though. Here are a few in-progress pictures. I'm using Raf's templates at 93%. It's a snug fit, but should work. There was a little trouble with the lower left cheek, but a little bondo can fix that. I also glued the keyhole in the back this morning as well.

eventHORIZON · Oct 6, 2014

A TRULY GREAT BUILD so far!!! Are you using Sintra for your helmet as well??? I just can't tell w/ the stencils glue on...just curious, cuz I had a vicious time w/ 2mm Sintra on my helmet...heat gun and boiling water proved to be a nightmare!!!

- - - Updated - - -

PS...what kinda glue are you using w/ the Sintra???

mcfarlj3 · Oct 6, 2014

eventHORIZON said:
A TRULY GREAT BUILD so far!!! Are you using Sintra for your helmet as well??? I just can't tell w/ the stencils glue on...just curious, cuz I had a vicious time w/ 2mm Sintra on my helmet...heat gun and boiling water proved to be a nightmare!!!

- - - Updated - - -

PS...what kinda glue are you using w/ the Sintra???

Thanks eventHORIZON, I really appreciate the support! Yeah Sintra is definitely not the easiest thing to work with. I'm currently ignoring the back plate for that very reason. I debated using sintra for the helmet, but decided to go with 1mm card stock. After trying to shape sintra for the other armor pieces, I thought card stock would be easier to work with for the helmet and the gauntlets. After I'm finished constructing the helmet/gaunlets I plan on using fiberglass resin to harden the cardboard and then use bondo, or some other filler, to smooth everything out.

As for glue, I used Loctite epoxy for plastics. It worked great even when joining just the edges of the sintra (like the curved part of the knees). I'm using an Elmer's craft glue and some hot glue for the helmet. I've been pleasantly surprised with the Elmer's glue.

mcfarlj3 · Oct 6, 2014

So, like I posted earlier, the knees were on hold for a while. I wasn't completely happy with the Sintra knee dart boxes, so with the help of my father-in-law, we made some new ones. I put bondo on the back side to be sanded down to achieve the sloping effect.

We also made the cone knee dart for the right knee out of an old wooden dowel. First we drilled a hole in the center. Then we put the entire dowel in the drill press to create a make-shift lathe. Using a file and sand paper, we shaped it into the correct shape.

He also had an old keyboard, so I used the keys for the shoulder and side greeblies/studs. Used a dremel to hollow out the inside, then sanded the tops of the keys to be flat. I use an epoxy to embed the blots into the keys. these will feed through the armor and be secured using a washer and nut.

I'll be working on those things as I continue to work on the helmet. Here's the keyhole and the extra dome supports (which I highly recommend despite the extra work). I'm currently working on the dome, then the ears.

mcfarlj3 · Oct 7, 2014

About a week ago or so I finished painting the chest and shoulder decals. I'm really pleased with how the chest turned out, but the shoulder didn't turn out as I had hoped. It still looks ok and I plan on touching it up once I have more time. I used stencils and masking fluid to paint the decals. In general, the armor is too "clean" looking for what I eventually would like, but so far I'm happy.

More work on the helmet last night. Finished putting the dome on except for the section where the dent will be.

mcfarlj3 · Oct 13, 2014

The past few days have been nothing but Boba Fett. I fiberglassed the inside of the helmet and have begun to paint the knees. The ears are taking longer than expected but I'm having fun putting them together. Since the helmet is taking longer than anticipated, the gauntlets seem to slipping out of the realm of possibility for Oct 31. I keep telling myself quality over quantity. Either way I'm sure it will get the job done for the office halloween party.

mcfarlj3 · Oct 17, 2014

I'm continuing to prep the helmet for paint. Several layers of Bondo on top, and a rough layer on the cheeks. Hopefully, I can lay down the primer sometime tomorrow, but I still have quite a bit of work to do. The ears are just taped on for these pictures. How does it look so far?