Finally, after more than a year collecting and preparing, here is my ROTJ Boba Fett! It’s hoped to be a mostly accurate version (inaccuracies, or improvements as I’d like to think, intended to be hidden from exterior view), aimed at the costume as seen in those few original shots from Jabba’s Palace (with some leakage from the skiff scenes), and questions, comments and/or critiques are very welcome! Each hard piece is fully layered, helmet to knee armor, except some topical shading and scratches. I’m going to include the link to the post for the helmet steps here under Boba Fett Costume (as this really is a complete costume), so folks starting here can find everything easily, but the helmet section will be under Boba Fett Helmet to maintain the site’s divisions.
I’d like to send special thanks for those whose guides I’ve followed, and I will credit them as I detail the work. Super special thanks to wizardofflight and RafalFett for their contributions and documentation for our collective knowledge of original parts and specifications; on the shoulders of these giants this work is possible for mere mortals. The biggest thanks of all goes to Art Andrews and Scott Kaufmann for providing and maintaining this forum, without which I’d probably still be thinking how awesome the Rubies costume is ( 
).
Here is my part list, grouped somewhat and in no particular order, with links where possible:
FP Premium cold cast helmet from animefan
“Bounty Hunter” range finder servo and RF transmitter/receiver from Hyperdyne Labs Hyperdyne Labs - Electronics - Bounty Hunter Rangefinder Up/Down Servo Controller Board
Blue Bird BMS-705MG servo BMS-706MG Low Profile High Speed Servo (Metal Gear) 4.6kg / .13sec / 32g
Scythe SY501012M 50mm Silent Mini Kaze Fans (2) https://www.amazon.com/gp/product/B00261ABFK
Tandy Leather Solid Brass Chicago Screws (5) https://www.amazon.com/gp/product/B001E5VOLE
3/16” Hole x ½” O.D. Rubber Washers https://www.amazon.com/gp/product/B00FSY257O
uxcell 3 Solder Lug Pin On-On 2 Position Slide Switch (6) https://www.amazon.com/gp/product/B007Q854MS
RF Light Kit from jc27
Dental Files (4) from bojaGun
Replica Resin Chin cup from bojaGun
Borden 3-hole Metal Connector https://www.allfordentist.com/metal-connector-only-prd-7829.html
Slim Deluxe T-Visor http://www.t-visor.com/shop/slim-deluxe/
Casio MQ-1 from eBay
Aker MR1506 10W voice amplifier (sold as Ivation brand) https://www.amazon.com/gp/product/B006TL5KWC
Pyle PDWM96 Wireless Microphone https://www.amazon.com/gp/product/B0007L8BQW
Hosa MHE-100.5 ¼” to 3.5 mm Headphone adapter https://www.amazon.com/gp/product/B000068O6B
Porelon Black Carbon Paper https://www.amazon.com/gp/product/B008K5ENE6
Trace-It White Transfer Paper https://www.amazon.com/gp/product/B00QBCALIM
ROTJ Gloves from Mike M.
Flight suit, Flak Vest, Neck Seal, Pouches, and Spats from Arkady
Rit Dye 39 Pearl Gray https://www.amazon.com/gp/product/B000GPGJKO
Jingle Bells 1” (3) https://www.amazon.com/gp/product/B002PIEAH4
Girth Belt from woodman
Boots from MOW Studios
Toe Spikes from JodoKast89
Chest/Back, Knee, Shoulder Armor, and Gauntlets from redkraytdragon
Dritz Knit Elastic 1” width https://www.amazon.com/gp/product/B0006O1ICE
Velcro strip 1” width locally sourced (Michaels)
Lithium Button Cell Battery Holder (2) https://www.amazon.com/gp/product/B00FHN4NZS
Lamin-x 148S Smoke 4” x 8” Universal Film Cover Sheet https://www.amazon.com/gp/product/B001P2D4LY
Knee Darts from JodoKast89
Collar/Cod studs from JodoKast89
Fettronics Chest Light Set in the RafalFett sequence http://www.fettronics.com/Showcase2.Htm
ROTJ Stencils from Darth Voorhees
6v CAMDENBOSS Filament Indicator light http://export.farnell.com/boss-enclosures/515205red6v/filament-indicator-red/dp/745327?Ntt=7453277
Generic Electric Igniter/Electric Match (no longer available, but like these https://www.amazon.com/HOODDEAL-principle-experiment-Connecting-accessories/dp/B01EX5F6WE)
Nitrocellulose https://www.amazon.com/Grams-Cotton-Magic-Tricks-Fire/dp/B01GQ93WDA
Flamethrower Nozzles and Gauntlet Rocket from JodoKast89
Glenross Dental Expander Disassembled from toolguy301
Gauntlet Darts from JodoKast89 via Deathproof
Arcolectric Momentary Push Button Switch (2) http://www.newark.com/arcolectric/t0916soaaa/switch-spno-black/dp/06WX0736
Brass Pipe Fitting, Coupler 3/8” to 3/8” Female https://www.amazon.com/gp/product/B001AZ3YFC
Brass Pipe Fitting, Flare Nut 3/8” O.D. https://www.amazon.com/gp/product/B001JYX7LA
Brass Pipe Fitting, Close Nipple, 1/4” locally sourced (Pastime Hardware)
Brasscraft 3/8” O.D. 20” Chrome Lavatory Supply tube https://www.amazon.com/gp/product/B001PMEP6C
Braided hose 5/16” I.D. https://www.amazon.com/Pressure-Braided-Flexible-Chemical-Resistant/dp/B00LX6LUGS
National Hardware 1 1/16” x 12” Continuous Hinge (4) https://www.amazon.com/gp/product/B000BPB2OW
Alcoswitch Push Button Switch (2) http://www.onlinecomponents.com/te-connectivity-alcoswitch-brand-mpe106d.html?p=10537557
Jetpack from MOW Studios
Jetpack Harness from Bigdane
Jetpack hooks and clips from full metal fett
Kam EZ Pak US Divers Scuba Tank holder (for buckle, straps) on eBay
Country Brook Design 2” Metal Round Triglide Slides (2) https://www.amazon.com/gp/product/B0047WO46S
Country Brook Design 1 ½” White PolyPro Webbing https://www.amazon.com/gp/product/B00E3DAWSA
Jetpack Beacon from Evolution Props on eBay
Jetpack Beacon Light Kit from jc27
ROTJ Vinyl Jetpack Decals from Lucky31 http://www.delucksdesigns.net/SWfett/ROTJBobaFett.html
Sugru Moldable Glue https://www.amazon.com/gp/product/B00KX6LTYM
ITT Canon XLR 5-Pin Female Receptacle on eBay
Generic On-Off Push Button Switch locally sourced (Al Lashers Electronics)
MrRCSound smoke system http://www.mrrcsound.com
Baomain 1NO 1NC AC 250V 5A Momentary Push Button Switch (1) https://www.amazon.com/gp/product/B019VQSVY0
4mm Gold Bullet Connector Plug (3 pairs) https://www.amazon.com/gp/product/B00DU4A86O
Turnigy 6S 22.2v 5A Lipo Battery https://www.amazon.com/gp/product/B00LF3QJYW
Horsehair Wookie Scalps, ROTJ Cape, ROTJ EE-3 from Molon Lab Studios (MLS)
Ammo Belt/Pouches from fenixprops on eBay
Patterson Photographic Print Squeegee http://www.adorama.com/PARCPS.html?cj_sid=ipugk2myg9015jde003db&cj_aid=10782535&utm_source=cj_4003003
Anti-Security Blade Rods from Mojo Fett (mojo_skywalker on eBay)
JVCC EL7566-AW Electrical Tape 1 ½” width https://www.amazon.com/gp/product/B000QDRRM0
Paints:
Model Master Schwarzgrun RLM 70 https://www.amazon.com/gp/product/B008JATIWY
Model Master International Orange https://www.amazon.com/International-Orange-FS12197-Enamel-5oz/dp/B006G1L3H6
Tamiya Model Color Enamel Paint XF-17 Sea Blue Net 10ml https://www.amazon.com/gp/product/B00F288UXY
Delta Creative Ceramcoat Acrylic Paint; Purple, Black (flat and gloss), Charcoal, Burnt Umber, Magnolia White, Straw (all from Amazon)
Floquil Caboose Red, CNW Green, Dark Blue, Southern Green, and Wisconsin Central Maroon, from eBay
Humbrols from humbrol.com
Krylon Colormaster Clear Gloss spray
Rust-olium Master’s Touch 2x Ultra Cover flat grey primer
Rust-olium Master’s Touch 2x Ultra Cover flat white
Rust-olium Master’s Touch 2x Ultra Cover matte clear
Rust-olium Universal Paint and Primer In One Hammered Black
Rust-olium Painter’s Touch 2x Ultra Cover Paint and Primer Satin Cinnamon
Klean-Strip Premium Stripper (spray)
Micro Mask https://www.amazon.com/gp/product/B0006O028U
Tamiya 40mm Masking Tape https://www.amazon.com/gp/product/B000BN9R1Y
Best-Test Pik-Up Rubber Cement Eraser (3) https://www.amazon.com/gp/product/B0028D8FGI
3M Imperial Wetordry 2000 Grit Sandpaper https://www.amazon.com/gp/product/B000MW91RE
JB Weld https://www.amazon.com/gp/product/B0006O1ICE
Zap-A-Gap CA+ Adhesive https://www.amazon.com/Pacer-Technology-Zap-Zap--Adhesives/dp/B00SXJJ2QI
Loctite Quickset epoxy locally sourced (OSH)
Miscellaneous tubing, tube fittings, copper strips, screws, nuts (plenty of those here 
), and paint brushes on hand. Here are the Dremel tool tips used:
[ATTACH]64090[/ATTACH]
All the new purchases came in at just under $4200, which includes (spoiler!!) a charger for the Lipo battery running the jetpack smoke generator, but does not include the year and a bit of my spare time, which truth be told I’d gladly invest again.
A couple of general comments about the process (I’d like to think “words of wisdom”, but that’s probably going too far) before we get to the interesting stuff. I bought all my Humbrols from humbrol.com which is really Hornby Hobbies. Nothing earth shaking here, just as with I’m sure most paint, some sits around longer than others and some goes quite quickly. I learned after a couple of inconsistent sprayings to thoroughly mix these little tins, not just shaking them (which I did first for a minute or so each) but with a toothpick, carefully stirring the contents to get the pigment settled to the bottom back into solution.
A recurring challenge through all these steps below that I’ll mention here was the real difficulty masking the damage presented for me. I wanted to rely on actual screen captures, but while it seemed I was living on the gallery pages showing the screen captures from ROTJ, there just aren’t enough detailed shots to map all the damage, and some pieces switch from hero to stunt to backup within a few frames, making deciding which damage pattern to use a bit nerve-racking for me. I scrolled through all the pictures from the various exhibits, trying to identify the screen-used hero pieces where they were included by tracking characteristic damage spots, and while mostly hit-and-miss, that did pay off a bit for the damage on the gauntlets. In short, I’m sure I spent more time masking, in most cases one tedious toothpick drop after another, and demasking than I did on preparation and painting, by a couple of factors if not orders of magnitude! It’s quite possible I was doing it wrong, spending way too much time daubing mask (only a few spots where there was enough solid mask to use a brush), but while it took a long time I ended up being very happy with the look of the results, and as a hobby my purpose wasn’t really to rush through everything. Even (or especially) on the helmet, where RafalFett’s stencils make deciding where to mask much easier, it was a very laborious task that took me weeks for each paint/mask layer. After all this I have a huge respect for those here that accept commissions for such work, and a much better idea of the skill they bring to our community.
One thing I wish I’d done more consistently was take pictures of the damage masking; I had some trouble locating the mask under the layers of paint just using the reference pictures I’d used when applying the mask, and I know I missed some in some places. However, as I had applied the previous colors uniformly rather than in selected areas as I’ve seen in some other builds, any place I thought I needed damage I could just carefully scratch through the top layers. I hope that technique will pay off in the future as the armor pieces continue to wear and weather with the unavoidable additional accumulated scratches as I troop with it.
