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Mandalorian costume WiP--Sek NeeglikSubscribe
  1. Member Since
    Sep 2014
    Sep 27, 2014, 5:01 AM - Mandalorian costume WiP--Sek Neeglik #1

    I'm writing this so I can keep my thoughts together. I'm going to try to keep all my costs documented. A quick background... I've been a Fett fan since I was a kid (40 now). I started to make a scratch costume many years a go, but did not have the money, skill, or ambition to see it through. This time I'll get it done. I am a also a gun nut. I have been teaching firearms for a little while and have some armorer experience. For job reasons, I have carried a gun to work for over 10 years now. Because of that, I want this build to have some real world logic to it. I know it's sci fi, but it's just the way my brain is wired anymore.

    This costume is for me. I don't have any current plans to join the 501st or Mandalore Mercs.

    Costs to date:

    Helmet-Lonewolf Executioner Helmet $190
    Jumpsuit-Blue nomex Flightsuit $6.
    Vest and neck seal-$80
    Balaclava-USGI Green nomex hood $1.
    Metal Armor (Chest, Shoulders, Ab, Back, Knees, Cod)-$165
    Cape/serape-USGI Shelter half $10.
    Home Depot Gloves-$20/3 pairs
    Backpack-$100 (DIY pack and army radio pack)
    Sash or girth belt-OD 550 Cord $5.
    Antique USGI pistol belt-$2
    Leather holster-$1
    Leather pouches-$15
    Cargo pockets-$40/2 sets
    Shin armor?-
    Elbow armor?-USGI elbow pads $3
    Boot spats-$20
    USGI Tan Tanker Boots-$35
    Long gun-Nerf Rayven and Hasbro E-33 $37.
    Pistol-Rubies Jango pistol $13
    Netting- $6
    Random Greebles-$20

    3mm Sintra Sheet-$40
    Adhesive- $10
    Xacto- $10
    Velcro- $20
    Heavy Duty Snaps-$15
    Dremel wheels-$6

    Paints used:
    Rustoleum primer for plastics.
    Rustoleum camo flat black.
    Rustoleum camo brown.
    Rustoleum camo tan.
    Rustoleum flat brown.
    Rustoleum Aluminum.
    Testors dark green
    Testors metallic silver
    Testors flat black

    I am starting this build with the following concepts in mind. I am planning a modern Mandalore suit with a light/medium armor hybrid. I will be using similar Jango/Boba Fett patterns, decals and color schemes. I would like this to pass as an alternative suit that may have been in Boba Fett's closet. The suit will have its own history and damage, so I'll be starting with non-damaged armor. I would like to use dull earth tones for the colors. I want the suit to be modular. I will have a backpack eventually, possibly a jet pack, but I'll be starting out with no pack. I will be using an old west-style serape cape covering. The serape will be patterned after ones Clint Eastwood used as the man with no name.

    I plan to purchase cheap DIY items and put things together to test colors and fit. I'd like to follow it up with upgrades to more canon accurate pieces as money allows. What I replace will go toward a play suit for my son.

    I am planning to have a small arsenal of weapons. First weapon will be a long gun. The first thing I'll be doing is modifying a Nerf Rayven. It will have a barrel extension, scope, and laser. I have a sling in mind that will work similarly to one of the pre-production Boba Fett blasters. I'm also going to be adding LED read outs for the side. I'm hoping to make the LEDs and laser trigger-activated. I plan to make a dart or arrow attachment to go into the barrel.

    The build will include a Westar pistol for a sidearm. Probably going to get a Rubies pistol and paint it for now.

    I also have a Hasbro E-33 blaster I'll be repainting. Resin replacements may follow these.

    Nerf Rayven:
    I have sanded down all Nerf logos and safety markings. I have also sanded down the digital camo molded into the sides of the gun. I have began to prime the barrel extension (Rustoleum primer for plastics). I will be adding a medium gray next, then a metallic silver layer.

    Scored a used navy blue nomex flight suit for $6. Fit is perfect for me. I'm taking the pockets off and going to try to bleach it or hang it in the sun to lighten it up a bit.

    Bought a trash can from Walmart to test possible armor design ($2.97). Also purchased the LED car accent lights for the side of the Rayven ($12.97).

    I am hoping to find a used USGI shelter half this weekend for use as a serape.

    That is everything up to this point. More to follow...

    Edited for updates to cost list: 03-30-17


    Last edited by Neeglik; Mar 30, 2017 at 12:30 PM. Reason: Updated cost list
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  3. Sep 27, 2014, 8:52 AM - #2

    Right on, man! Stoked to see what you come up with.
    Quote Quote Posted from Android app
  4. Peregrinus's Avatar
    Member Since
    Jun 2007
    Sep 27, 2014, 1:29 PM - Re: Mandalorian costume WiP #3

    What are you using for the extension? The Rayven has that convenient universal attachment lug at the muzzle, so you could use one of the barrel extensions from something like a Longstrike or Recon or Spectre. Personally,I think it looks best with the one from the Spectre. Here's a link to a blog of someone who did just that.

    You can also hunt for a simple woven poncho to use as a cape, and it would be accurate to the concept art.

    I'm presuming you are already aware of how far off the Rubies Westar and Hasbro EE-3 are. Unless you're really small, the underscaling of the EE-3 will be painfully visible. And I ended up using two of Rubies' Westars to combine into a single custom one (my build, so far, should you be curious), it was so unsalvagable as anything remotely close to movie-accurate. If you want something that looks like Jango's blaster, you can probably scavenge some bits off of it, and stick them onto a scratch-built base. There are darn good blueprints on here, and the barrel and barrel sleeve diameters are convenient plumbing/electrical pipe/tubing diameters. The last toy Star Wars weapons that were usably close to their prop analogues were the budget-model Luke and Vader "ForceFX" lightsabers, Hasbro's DH-17 dart shooter, and the old Kenner E-11 (that last admittedly with a lot of work).

  5. Member Since
    Sep 2014
    Sep 27, 2014, 2:40 PM - Re: Mandalorian costume WiP #4

    I'm using the Nerf Longstrike extension. My son and I have a Spectre, but do not have the extension for it. I'm going to keep an eye out for one though. Like I said above, I want this build to be modular in nature, so having a second extension is not a bad idea. My son hasn't picked out a nerf gun for us to mod for him yet. I painted a rough camo job on a Longshot last year, and he loved it. I kinda like the look of the Nerf Zombie Slingfire, but we haven't got one yet.

    I'm aware of the size difference in the Hasbro and Rubies toys. My boy will love the guns once I'm done experimenting with colors and weathering patterns. Eventually, I'll want to get the full size resin models. A lot of what I am going to be doing this year will be the version 1 or prototype, if you know what I mean. I do like how you're using two guns to build one good one!

  6. Peregrinus's Avatar
    Member Since
    Jun 2007
    Sep 27, 2014, 7:30 PM - Re: Mandalorian costume WiP #5

    There are a couple Spectre barrel extension on the 'Bay right now. $20/free shipping. I have one I'm not terribly attached to that I'd be willing to part with for far less than that. PM if interested and we can sort out details.

    I'm a big fan of both modularity and test-runs/prototyping. My initial Mando interest was to make a Clone Wars era Fenn Shysa (color-corrected from Marvel's atrocious coloration technology/technique of the early '80s). Metal armor. Lots of "play features", i.e. working/moving bits. While working on that I got fired up to do a custom as well. Both of those, however, are going to be several years yet until they are fully realized. So, partially to familiarize myself with some elements that I will be making out of metal further on that I'm either scratch-building out of sintra or got the vac-formed versions of to check fit and use for reference. I'm also modding a Hasbro Boba Fett helmet toy just to see how decent I can make it look. So I decided to put them to use, along with "waster" parts I got from the guy who did the initial cutting and rough-forming of my torso plates (collar and cod were just going to get tossed). Those, plus pieces from those two main costumes that I do have sorted out, and a couple pieces I'm making just for this one, have all become what I call my "v0.5" kit. That's what the other links in my sig, over in that Westar thread, lead to.

  7. Member Since
    Sep 2014
    Oct 1, 2014, 11:00 AM - Re: Mandalorian costume WiP #6

    I picked up a shelter half and have made a serape out of it. It needs weathering, and maybe a bit more damage, but I like the look of it so far.

    I saw some leather straps at the surplus store that I'll probably go back and get. Very interesting hardware and hooks. I'm not sure what they came from but it looks ideal for either a sling or belt/holster parts. *edited to add that I got these. They are part of the shoulder straps from a European military pack. I'm 99% sure I'll be using it for the sling harness for the Rayven.

    I have removed most of the pockets from my flight suit. I plan to replace the remaining zippers with Velcro.

    I've cut chest armor from the trash can I purchased. I went with the child size for test purposes. It looks ok for my boy, but I think I'd prefer something thicker for me.

    Hopefully, I'll have some stuff completed to where I can start taking pics soon. More to follow...
    Last edited by Neeglik; Oct 2, 2014 at 6:34 AM.
  8. Member Since
    Sep 2014
    Oct 10, 2014, 7:27 PM - Re: Mandalorian costume WiP #7

    I have removed all but one of the pockets on the flight suit. I'm probably going to remove the collar also. I've given it a pretty heavy dose of overspray with Rustoleum camo tan, brown, and black. The original dark blue was just too dark for me.

    The serape is done for now. I added some graphics with the Rustoleum camo black. Nothing much, but I wanted more than just OD green. I weathered it the same way as the flight suit.

    My barrel extension is almost done. I'll be gluing on a couple things, then touch ups on the paint and a dull coat to finish it off. The Rayven is coming along, but still need to figure out the wiring for the electronics.

    I cut up some OD 550 cord for use as a girth belt. I wanted to do something different than the standard maroon colored belt from Boba Fett.

    I plan to go back to the surplus store. I have my eye on an air crew rig they have at a good price. It has at least 4 cobra buckles on it. I think they would make a better futuristic look than plastic fastex for belts, vest, pack harness, etc.

    I am contemplating using an USGI OD sleep shirt for my vest. I'm gonna look at them a little closer and see if it will work or not.
  9. Member Since
    Sep 2014
    Oct 13, 2014, 7:55 AM - Re: Mandalorian costume WiP #8

    Scored a 1 piece rubies Jango Fett helmet for $40. Hopefully it will arrive this week and be one of the better examples to come from Rubies. Either way, I'll at least get to experiment with my color pattern and modding of a helmet.

    I hope to start sewing my 550 cord together for the girth belt this week. Not sure how that's gonna turn out, but we'll see...

    WiP pics...

    Front of flight suit and serape so far.


    Barrel extension so far, along with leather for sling.
    Last edited by Neeglik; Oct 13, 2014 at 8:16 AM.
  10. Member Since
    Sep 2014
    Oct 22, 2014, 10:43 PM - Re: Mandalorian costume WiP #9

    Rubies Jango Fett 1 piece arrived. Overall good condition for what it is. Some warping. I applied some heat and got some of the overly oval shape out of it. I applied some USGI helmet pads to the inside so it doesn't spin around on my head. It is short, my chin is visible. Again, this will be a temporary/training helmet that will ultimately go to my 6 year old. I wanted more Boba Fett colors, so I went with a green and red colors. I plan to cut out the visor and add a full size one. Ultimately it doesn't look too bad, but I definintely look forward to getting a better bucket.

    Grabbed a Rubies Jango pistol. I plan to paint it silver and/or black. I'll probably glue or otherwise reinforce it. It's pretty cheap.

    Picked up some random lawn tool stuff for adding to the costume or possibly to my future backpack.

    Also picked up some better needle and thread for the paracord girth belt that I haven't started on yet.

    Pics to follow.
  11. Member Since
    Nov 2014
    Dec 8, 2014, 11:25 AM - Re: Mandalorian costume WiP #10

    Like the green.
  12. Member Since
    Sep 2014
    Dec 8, 2014, 7:20 PM - Re: Mandalorian costume WiP #11

    Haven't updated in a while.

    Jumpsuit collar and all pockets are removed. Need to re-sew some seams.

    Nerf Rayven got hit with the dremel. The removal of some of the stock and thumbhole grip, plus the addition of a Crossman scope and laser sight really help de-Nerf the look. Gonna find some bondo or body filler to finish it up. Here's a pic with some of the cuts made and parts laid next to each other.

    I finished sewing together my paracord today. I need to figure out what straps and buckles I want to use to finish the girth belt.

    I ordered a pair of Boba Fett cargo pouches. They should arrive soon.

    I wore my Rubies helmet and onesie jumpsuit and grabbed my Hasbro Boba Fett blaster for my Halloween outing. Pretty lame setup, but I did get a lot of compliments. Everybody loves the Fett! I told them to just wait and see what I do for next year!!
  13. Member Since
    Sep 2014
    Mar 12, 2015, 4:50 PM - Re: Mandalorian costume WiP #12

    Haven't done much lately. I did finally get my cargo pouches. The first set came as two of one side. One of them has some crappy stitching too. I notified my source and they sent two of the other side, giving me two full sets. If anyone can use a set of ESB belt mounted cargo pouches, drop me a line....

    Lately, I've seen a guy who took a modern US military approach. I'll see if I can link his pics. I think im going to steal some of his ideas. Mainly thinking about linking the armor with buckles, and using some night vision and light attachments from the military for the helmet.
  14. Member Since
    Sep 2014
    May 10, 2015, 9:59 AM - Re: Mandalorian costume WiP #13

    Still haven't done much. Girth belt and blaster are still sitting unfinished, although I did free up the area around the rear of the pistol grip and am happy with the result.

    I have been collecting parts. I have a new visor on the way for the Rubies helmet. I also have airsoft ARC accessory rails with Princeton Tec MPLS led lights and side armor for eventual helmet mods. I ordered boot spats. Next looking to get belt and belt pouches, gauntlets, vest and chest armor.

    This should give me a decent lightweight armor variation in time for Halloween and possible wear to The Force Awakens viewings. I'll add and improve during 2016.
  15. Member Since
    Sep 2014
    Jan 10, 2017, 4:09 PM - Re: Mandalorian costume WiP #14

    It has been a long time, but here’s an update…

    Metal, basic armor set (Collar, Diamond, Chest, Ab, Cod, Back, Shoulders, and Knees).
    Vest with attached neck seal.
    Executioner mando helmet.
    USGI tanker boots.
    USGI pistol belt (old style).
    Surplus ammo pouches.
    Various greeblies and accessories.

    Armor is just about complete. Need to decide on my attachment method to vest.
    Helmet is cleaned up and painted. Will add some internals at some point.
    Sticking with my theme of having modular gear. Will be able to adjust here and there to change the look.
    Restarted work on a girth belt, but have not finished it.
    Still debating on loincloth and kama options.
    Still working on Nerf blaster and will continue modding it.

    Pics and descriptions to follow…
  16. Member Since
    Sep 2014
    Jan 13, 2017, 8:41 AM - Re: Mandalorian costume WiP #15

    A few pics as promised...

    Unboxing of my new helmet:

    Mostly finished:

  17. Member Since
    Sep 2014
    Jan 16, 2017, 11:03 PM - Re: Mandalorian costume WiP #16

    Temporarily attaching armor to vest.

    I think Velcro will hold, but I'll probably add a couple snaps to help hold the weight.
  18. Member Since
    Sep 2014
    Feb 9, 2017, 8:26 AM - Re: Mandalorian costume WiP #17

    Making progress.

    Almost finished modding my blaster. Have started to paint it.

    Have also tried painting the tan tanker boots. They need a bit more weathering, but they're almost there.

    Plan to order some 3D-printed gauntlets and make a girth belt next.
  19. Member Since
    Sep 2014
    Feb 11, 2017, 1:08 PM - Re: Mandalorian costume WiP #18

    So I have a few minutes and wanted to get a few thoughts down...

    Metal armor pieces are completely painted. I have attached industrial-strength Velcro to the back. I am now adding heavy duty snaps to add strength to the attachment. I will be starting to sew on velcro and add snaps to the vest this weekend.

    I passed the Rubies helmet on to my son. He digs it and at 8yo, it fits him well. I bought a Lonewolf Executioner helmet. Great helmet and fits much better than the Rubies. I decided to add some communication antenna vs. the traditional range finder stalk. I experimented with a couple of color schemes ie. tan, brown, and blue. I may add pics of these later. The tan actually looks very cool if one was interested in maintaining the skull look of the Executioner helmet; but for this build, I decided I wanted to stick closer to traditional Boba Fett colors. I have cut out all the front, side, and rear vents and need to finish placing some screening behind them. I plan to add a fan and some amplified voice options.

    I am undecided on how I will attach a backpack/daypack/jetpack yet since I have not finalized my concept for it. I have a number of materials for it though to include heavy duty cardboard and polymer tubes, military whip antenna, lunch boxes, hoses, led lights, Graflex flash body, and various other plastic and metal parts. For now however, no pack.

    Main Weapon:
    My main blaster rifle is almost done. I cut the thumbhole portion of the stock and grip of the Nerf Rayven. I also removed the trigger, magazine and mag latch areas, and the top door for clearing dart jams. I filled the areas in with bondo. I have also added bondo to seals seams, fill in some of the accessory rails, and fill screw holes. I cut out some of the slits in the barrel, and added few holes for additional "gas ports". I have added a red led bike light for the side. I've also added a .22 scope, Magpul grip parts, a hose nozzle, a broken screw driver handle, some keyboard keys, a scope wrench, a Gameboy circuit board, and a few knobs. I am still fleshing out the primary colors and weathering. I still need to configure the sling and add the laser sight. I'm pretty happy with it. It may look a little Nerfy still, but I think it's unique enough to pass the average eye.

    Secondary Weapon:
    I have not done anything to my Rubies Westar-34 other than covering it in chrome paint. I may pick up an additional one to experiment with modifying, however I am considering buying a legit prop pistol version of this or maybe some other Star Wars pistol (Boba Fett's).

    Tertiary Weapons:
    I have bought a heavy duty curtain rod to build into a fighting staff. I have not started working on it yet. I have some 3mm sintra and plan to pick up some 6mm sintra for building a couple blades and sheaths. I also am planning to pick up a biker scout pistol and holster set to add to one of my boots.

    Girth belt:
    I think I'm going to abandon the 550 cord idea. I have some red polyrope to use. I may mix the two. I'm still undecided, but I'll be close to focusing on this project again soon.

    I initially toyed with using my gray Five Finger shoes. I think they are look unique enough, but they are just too thin looking to fit with an armored suit. I picked up some tanker boots for a decent price. I wasn't sure about the all tan tanker boots with the rest of the costume being mostly grays and greens, so I picked up some acrylic paint and have tried to break up the tan. I add some lines and patterns here and there and did some weathering. I also added some Mando numbering on the back. I think they turned out ok.

    Ammo Belt:
    I have a 1940's-ish era USGI pistol belt with metal buckles It is very weathered, but I think I may add some gray and/or some greeblies to break up the traditional look of it. I added my Boba Fett cargo pockets to it, as well as a tool belt holster (for drill, heat gun, etc), and two MP5 magazine pouches (leather and canvass). I got the mag pouches off ebay at a great price. I like the look of them a lot. For now, I have painted 1"x2"s sections of wood and placed them in the pouches to fill it out. The tool belt holster has three slots in front for accessories. I placed a few odd ball looking tools in them for now. I'm not sold on this configuration as is. I just feel like it could be a lot better and plan to keep an eye out for better options.

    Will add more as progress is made.
    Last edited by Neeglik; Feb 11, 2017 at 1:18 PM.
  20. Member Since
    Sep 2014
    Feb 19, 2017, 8:06 PM - Re: Mandalorian costume WiP #19

    I got some more work done this week.

    Girth belt is about 75% done. I need to add straps and buckles, reinforce the gluing with some needle and thread, and then weather it.

    I started attaching snaps to my flightsuit and vest. The knees went on just fine. I may get some more vest work done tomorrow.

    I picked up an oil pan at Walmart to serve as my main backpack body. The size is just smaller than my back plate. I cut out a slot to insert a thin lunch box style box I had lying around. This will provide a main compartment for whatever I'll be carrying. I've already decided how it will attach to the back plate (QD buckles). I think it will look good once I sort out a final configuration for the greeblies I'll be adding.

    I also picked up an 1990's Hasbro E-11 stormtrooper blaster today. Another weapon to throw in the arms bin.
  21. Member Since
    Sep 2014
    Mar 1, 2017, 9:52 AM - Re: Mandalorian costume WiP #20

    I'm still sorting out the possible backpack. Will throw up some pics shortly.

    My girth belt is 95% done although I may have made it a hair too big. If the length isn't too bad, I will reinforce it a little more with some sewing and then weather it a bit.

    First bits of velcro are on the vest, planning to add snaps before the weekend.

    Need to get another shelter half and experiment with a Kama and loincloth.
  22. Member Since
    Sep 2014
    Mar 1, 2017, 9:59 AM - Re: Mandalorian costume WiP #21

    Couple pics...

  23. Member Since
    Sep 2014
    Mar 7, 2017, 7:12 AM - Re: Mandalorian costume WiP #22

    Found this yesterday. I believe I will use it for my pack instead.

  24. Member Since
    Sep 2014
    Mar 30, 2017, 12:38 PM - Re: Mandalorian costume WiP #23

    Armor is almost done. I will have some of the Velcro adjusted and still have to attach some snaps, but it doesn't look too bad.

    I messed up and ordered the wrong size 3D printed gauntlets. Now I'll have to wait another month or so to get the right ones.

    Layed out some greeblies for the radio pack. See pics below. I'm still toying with a harness/carry system.

  25. Member Since
    Sep 2014
    Apr 6, 2017, 3:18 PM - Re: Mandalorian costume WiP--Sek Neeglik #24

    Still working up concepts for the backpack. I am getting close to a finished version. Below are two variations. One with the MP5 mag pouches, and one with a buttpack and some hosing.

    Been focusing solely on the pack lately and haven't done much else. I have some vacation time and will try to wrap up the snaps for the back plate, finish up preliminary work on the pack, start work on cleaning and modding the E-11, and start doing more test fittings to see how well everything is going to integrate. Hopefully I'll have a lot of this done before the second set of gauntlets arrive. That way I can focus all my energy on prepping and painting them.
    Last edited by Neeglik; Apr 8, 2017 at 8:25 AM.
  26. Member Since
    Sep 2014
    Apr 8, 2017, 8:22 AM - Re: Mandalorian costume WiP--Sek Neeglik #25

    Got a couple more greeblies that I've been fooling with (bread tube and Altoids mint can auxiliary control panel) added on. Also threw a snap link and an old game cartridge on.

    Started testing some fastex/parachute/side-release (whatever you wanna call them) buckles. I think they'll work just fine!

    Here's how she sits currently...

    And here are a few from the other night's full dress testing...

    Last edited by Neeglik; Apr 8, 2017 at 8:48 AM.

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