asky,
Looking good so far here's a link to that might help with new armor
http://tdh.prop-planet.com/viewtopic.php?topic=4949&forum=4
It's the link to the start of my Boba suit. I haven't examined the Jango armor in great detail but this should be close. I used Plexiglass for the armor and you can see a piece of it here in the above link.
There is another link of my more finished armor, but the picture links are bad so I'll have to fix them at a later date. Or maybe just take new pics.
I'm not sure how much access you have to tools but to make my armor here's what I did:
Plexiglass comes with two side protective "seran" wrap. Leave this on. I got a sharpie marker and one of the templates that is floating around TDH, and traced out the first chest piece. The plexi I used was 1/4" (+-). Then I used a fine, but not too fine of tooth on a table saw to cut it out the major sections. When cutting into the corners you have to becareful not to cut all the way as the saw blade is rounded and will cut deeper underneathe than on top. You'll be able to see through the plexi to understand what I'm saying. Once I got those corners close I took it to a band saw (hand saw will also work here) and squared out the corners.
You can take the seran wrap off at this point. I took the piece over to the bench grinder which has a rotating wire brush on the other side. With the grinder spinning I rounded off the top edge all the way around. Becareful in the corners as you'll take off more material then you want.
After that I went inside and turned on the stove. We have a gas stove so I used that as my blow torch I heated up the plexi while wearing oven mits. Now some people will tell you to use a heat gun instead so the plexi doesn't catch fire, but the stove is SO much faster. You just have to keep it moving so it won't start to burn. When it starts to become bendable I stuck it inbetween a few tshirts and pushed in the center so it would bow out. This part you can't see in the pic that was taken before I heated it.
After that sand it with 100 grit followed by 200 grit. And then spray paint. I did find that spray paint took longer than normal to cure in order to pass the finger nail test.
In the above thread you can see the shoulder bells which were plexi and have gone through the whole process as above.
anyways,
good luck,
-matt
