The Armor is custom sculpted and vac-u-formed in 1/8" thick plastic. The armor consists of 12 separate pieces plus to two gauntlets (discussed elsewhere).
Gorget (Collar Plate)
- Right Spaulder (Shoulder Bell)
- Left Spaulder
- Right Breastplate (Chest)
- Leftt Breastplate
- Center Diamond
- Abdomen plate (Ab)
- Kidneyplate (Butt Plate)
- Right Poleyn (Knee Guard)
- Left Poleyn
Each piece of armor was labeled on the back with red sharpie indicating where the armor attaches on the costume (i.e. 'L' for left, 'R' for right). Floquil model train paints were used to create Fett's unique look and weathering. Various painting techniques consisting of airbrush, paintbrush, and a spray bottle for weathering helped in making Fett come alive. Along with the helmet, the paint scheme for Fett's armor varies between concept to screen. During pre-production, Fett's armor was going through different color changes that were scraped last minute and an all military green version of Fett was finally decided upon for ESB. However, the original pre-production armor was revisited for the release of ROTJ. It isn't 100% clear, but speculated that the ESB armor was repainted and used in again for ROTJ. This theory is based on and supported by the Art of Star Wars Exhibit reference photos.
(Right & Left Knees from the Art of Star Wars Exhibit. Note: Left Knee same as Pre-Production 2 costume)
(Right & Left Knees from the Magic of Myth Exhibit
(Right & Left Knees from Pre-Production 3 & the Empire Strikes Back
The Knee Guard Armor, or Poleyns, is made from Vacuformed 1/8" plastic. Each knee is made from three separate parts, the face, left side and the right side.
A 1" wide white elastic band was glued around the back. It was noted that the Knee's would constantly fall down during filming, so it is assumed that the elastic strap was the only thing that held the knees in place.
The original props where marked on the inside face with an 'L' or 'R' with a red sharpie to indicate 'Left' and 'Right'.
In the Empire Strikes Back, during the Carbon Chamber scene, the Knees where attached upside down. Concept drawings reveal that this may have been intentional, although incorrect throughout the rest of the film as well as in Return of the Jedi
The only found items on the Knee Guards consist of the Rocket Dart Launchers, that are yet to be all identified.
Digital Chest Display
aka DIGITAL LIFE SUPPORT SYSTEM READOUT
Esb chest display top.gif
Esb chest display bottom.gif
(Animation of the complete Top sequence and an incomplete Bottom sequence)
Information for this display has been gathered from publicity photos and frame by frame viewing of the carbon freezing chamber scenes from The Empire Strikes Back.
The display consists of 20 LED light-bars on the top divided in five sets of four. The bottom consists of 5 LED digits and is powered via batteries which were stored in the left cargo pouch that hangs off the Utility Gun Belt. The electronic cord for the chest light can be clearly seen coming from the cargo pouch, running under the Utility Gun Belt, and running under the belly armor of the Preproduction
2 costume. Jeremy Bulloch independently verified that he turned on the chest light via a switch in the left cargo pouch. It should also be noted that on the Preproduction 2 Jet Pack the BNC Connector is labeled "Supply to Digital 6 volts + on centre pin", which could have been the original connection for the power supply.
It was generally believed that the chest display was not turned on during the filming of Return of the Jedi, however, the illuminated display can be seen in several early publicity photos and in HD screen shots of Jabba's palace.
RotJ HD 036.jpg
(This image is reputed to be the electronics used for Boba fett