Wow Wow Wow!
Super impressive. The right gaunt is definitely harder to make and you pulled it off beautifully. I'm a dad myself and made a Jango costume for my son (5) but I didn't go into the level of detail you have here. I've thought for a while that there is a need for good quality kids fett stuff. Let's face it, most of us aren't kids anymore but some of us do have kids who we see as our little costuming partners.
As far as reproducing these, wouldn't it be easier/cheaper to vac-form them in styrene?