The Flight Suit, or Jumpsuit, appears to be made from a pair of unidentified coveralls. However, it is possible that the flight suit is an original design. It is assumed that the Flight Suit from ESB was reused for ROTJ. The ESB 'blue' color can still be seen under the sleeves and pockets of the flight suit. For ROTJ, the color was faded to gray (intentionally or not) with light weathering. Weathering can be done with an airbrush, or spray paint, with a misting distance of four feet, using brown, black, gray and rust colors.
The Flight Suit includes a long sleeve and a short sleeve for each arm, a neck seal, two thigh pockets and two shin pockets and and two ankle ties (ESB only).
The neck seal is attached to the jumpsuit collar. It is quilted with five ribs and made from a separate material known as Poly Pro Twill (aka 'tackle twill'), with a front Velcro and Hook & Eye closure. The tackle twill material has a sheen and a matte side to the fabric and should be sewn matte side out.
The flight suit worn during the stunt shots in ROTJ was on display at the Magic of Myth Exhibit
The material appears to be a cotton twill. The color of the jumpsuit is dyed a light medium blue-gray. Royal Blue and Pearl Gray are two Rit Color dyes that create the best color. The Jumpsuit will require a little bit of weathering that can be done with an airbrush, or spray paint, with a misting distance of four feet.
THE ENERGIZED BLAST DISSIPATION VEST
The Padded Vest (nicknamed Flak Vest) is made from a light gray material called Poly Pro Twill (aka Tackle Twill), which is 100% polyester. It is used for the backing on athletic embroidered letters, found on letterman jackets, etc.
There are two distinct sides to the Twill material, a sheen side and a dull side. The vest is made with the sheen side out, but weathered with light tans, browns and black to dull the shine. It has a Velcro closure along the back and two cut-outs at the shoulders for the Rocket Pack harness to pass through.
The vest is the main part of the upper costume as all the major armor attaches to it. Brass grommet eyelets were added to the front and shoulders of the vest allowing the armor to attach to it using T-Nuts.
Power Armor Liner:
Liner shirt with micro energy field projector and two layers of thin ceramic plates. Disperses physical and blast impacts, reducing injuries and likelihood of knockdowns. Added protection from fire, acid, intense heat and cold." -The Essential Guide to Weapons and Technology
Utility Storage Packs
The Utility Storage Packs (aka hip pouches) are made from the same material as the flight suit and dyed most likely in the same dye bath. Popular color choices is a combination of Rit
Pearl Gray and Royal Blue, or just Evening Blue.
The material appears to be cotton twill.
Note that the right and left pouch flap are going the same direction (they go opposite on the Return of the Jedi
pouches). It should also be noted that the right pouch is a different size and shape as the left.
Two RC Dryshift batteries were inside the pouches to power the Jet Pack at one point; they may have been later removed due to weight. An 'ON/OFF' switch to turn on the Chest Lights was also noted to be in these pouches.
The pouches attach under the utility gun belt and is most likely stitched directly onto the honor sash. An example of this is seen in the Art of Star Wars Exhibit. A 1" strip of black Velcro
was added to the top of the pouch and the backside of the utility gun belt to help hold it in place.
Return of the Jedi Storage Packs
The Utility Storage Packs (aka hip pouches) are made from a cotton twill and dyed brown. Both pouches are identical to each other in size and shape. The only visible difference is that the right pouch flap opens to the left, while the left pouch opens to the right.
Originally two RC Dry Shift batteries were inside the pouches providing power to the Rocket Pack. However the pouches are often seen either completely empty or with a cotton ball inside them.
A small piece of denim fabric (or 'jean' material) is stitched to the backside of the pouches, creating a loop for the Utility Gun Belt to slide through.
The Return of the Jedi gloves are the same style as the Empire Strikes Back
, but are a lighter grey.
The gloves have white strips hand-sewn to each finger as well as a white square on the top side of the hand. They have light padding under them to give it a quilted look. At the base of the palm is a button and Velcro closure. On the left hand, the white square is slightly smaller than the right to adjust for the wrist gauntlet.
The Hood, or balaclava, is generally overlooked or ignored by most members since it is never seen and not very comfortable (too hot). Not much is known about the hood, but it is quilted along the top of the head and smooth down the back. It also has a long chin strap that loops through the D-Rings inside the helmet. The neck of the hood is tucked inside the turtle neck of the flight suit.
The Boot Gaiters, commonly referred to as spats, which covers the top of the boot and the cuff of the Return of the Jedi flight suit. They are made from a cotton twill material with a 1" Velcro closure on the side.
The Boots are most likely a modified found item, but the correct style boot has not yet been identified. A pair of boot Gaiters, or 'spats', where wrapped around the ankle.
A set of spikes were attached to a thin metal plate and glued to the sole of the boot and scewed down. The spikes have been identified as the pivot point on the Sweep Arm found on a JA Michell Engineering Hydraulic Reference Turntable.
Jeremy Bulloch has been noted to have said that the boots where very uncomfortable to wear.
Empire Strikes Back Cape
The Cape measures approximately 30"x36" with a 6" orange stripe. It is still unclear if this cape is an original design or a found item. It does appear to be a solid piece of fabric (not three pieces stitched together) similar to a wool horse saddle blanket.
The cape attaches to outer left Collar Stud and to the Back Armor next to the Rocket Pack slot.
Return of the Jedi Cape