A newbie's attempt at making a "fresh" Boba Fett armor

funkz

New Hunter
Hello everyone and welcome to my thread!

In this thread, I'll try to document my progress in making the "fresh" Boba Fett costume. I'm somewhat new to making costumes, as this will be my first everything!

I'll try as much to list the materials and methods used so this thread can also serve as a resource for other newbies.


The helmet
Materials/tools used:
  • Prusa MK3 i3 MK3S
  • eSun PETG 1.75mm Solid Gray printing filament
  • Sandpaper (120-600 grit)
  • Gorilla CA glue
  • Simply SP-037 Car Spray Putty (Used as filler primer)
  • Autotek ATOOTBB500 Truck Bed Liner Spray Paint, Black

For the helmet I'm going to be using my 3D printer to print out all the parts. Since my printer's workspace is too small to print the entire helmet at once I've had to split it up in 4. The main parts of the helmet is printed with 0.20mm layer height with 15% infill.

2021-07-27 21.04.24.jpg


Each quarter of the helmet takes approximately 24-32 hrs to complete printing
2021-07-28 19.30.33.jpg


Some more finished parts
2021-07-30 13.55.32.jpg


I used a lot of CA glue to put the parts together

2021-07-30 13.55.42.jpg


After some light sanding:
2021-07-31 17.14.02.jpg


Next it's time to apply a coat of filler primer, for this I used Simply Car Spray Putty that I found locally
2021-07-31 19.59.42.jpg


After each coat of filler primer, I let it dry for at least 2 hrs before sanding it down again. The goal is to eliminate all visible print lines on the helmet
2021-08-01 17.43.30.jpg


Meanwhile, we're gonna print the small parts for the helmet. This time I'm using 0.10mm layer height in order to reduce sanding and make the small details stand out more

2021-08-01 17.45.20.jpg


Lightly sanded and cleaned the small parts
2021-08-01 18.40.33.jpg


Test fit of the small parts to make sure they're good to use. Left side of the helmet here
2021-08-02 22.20.15.jpg


Right side of the helmet with view finder in up and down position
2021-08-02 22.19.54.jpg

2021-08-02 22.20.05.jpg


Everything fits! So time to apply a coat of primer to paint later
2021-08-03 17.12.15.jpg


Meanwhile I cut out a piece of a grinding shield visor to for the helmet. As you can see here, the print lines are entirely gone (apart from corners that were hard to reach, but this is gonna be covered up anyway.
2021-08-04 16.59.57.jpg


Before applying any paint, I'm using a truck bed liner spray (Autotek Black) to give the helmet that rugged surface
2021-08-05 17.37.45.jpg


This is all the progress so far. Right now I'm trying to let the paint bed liner paint dry for at least 24 hrs before I proceed to the next step.

Feel free to post a comment, feedback or give some critique to some of the methods I've used. For now, that's all I have.

See you next post!
 

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Hello everyone!

I'm back with another update. Unfortunately my green paint didn't come in yet so decided to do the red rim and black cheeks first.


The helmet
Materials/tools used:
  • Prusa MK3 i3 MK3S
  • eSun PETG 1.75mm Solid Gray printing filament
  • Sandpaper (120-600 grit)
  • Gorilla CA glue
  • Simply SP-037 Car Spray Putty (Used as filler primer)
  • Autotek ATOOTBB500 Truck Bed Liner Spray Paint, Black
  • Humbrol Maskol
  • Humbrol Metallic Silver No. 11
  • Rust-Oleum Claret Wine Satin Gloss
  • Rust-Oleum Black Matte
  • Rust-Oleum Khaki Gloss
I put a layer of Metallic Silver (Humbrol No. 11) in spots where I know I wanted the beskar to show up underneath the chipped paint and then put some liquid silicone (Humbrol Maskol) in spots to peel off later
2021-08-06 16.33.10.jpg


After a few coats of Rust-Oleum Clarinet Wine spray paint
2021-08-06 16.58.23.jpg


Painted the small parts with Rust-Oleum Khaki, Clarinet Wine. The stalk for the view finder I used Humbrol Silver No. 11. The viewfinder itself still had some visible print lines, so that got another coat of filler primer for sanding later
2021-08-06 19.08.03.jpg


Forgot to take a picture once the red paint dried, so sorry for that. Masking up the bucket to apply some Rust-Oleum Black Matte for the cheeks
2021-08-07 15.50.07.jpg


Now just have to let it wait to dry for another 24 hrs before I peel of the masking tape.
2021-08-07 16.01.13.jpg


Bonus pic: I found my old Jango Fett costume sans helmet
2021-08-06 17.30.02.jpg


More updates coming next week, see you then!
 
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