JSmails Holiday Special Boba Build

J

JSmails

Active Hunter
Hello.

Every year we have a Star Wars Holiday Special event at a small theater that is a toys for tots fundraiser. They play the special 3 times that evening and we have a lot of cosplay characters from that special. Acrobats, Wookiees in robes, etc. But we currently don’t have a holiday Fett. So I thought I’d take a shot at it. I don’t want to spend a lot of cash on the costume, so I’m scratchbuilding. Nobody makes the holiday Fett parts anyway.

I’m starting with the helmet. Progress:
https://imgur.com/ULxvqpW

https://imgur.com/E7XZX9P
Next to the other scratch built Fett helmet I made 3 years ago.
https://imgur.com/ZTuMaPr

Custom cut visor area.

https://imgur.com/u5ze0sE

Resin.

https://imgur.com/cVleSr2

https://imgur.com/GVbKQQl
Custom ear piece.

https://imgur.com/bYNtr3L

https://imgur.com/A1s4Wtn

Start of bondo/sand process. I’m no good at this at all.

https://imgur.com/YgE7021

https://imgur.com/T6bfKYG

https://imgur.com/zAP08Pi

https://imgur.com/HxU5b2p

https://i.imgur.com/QtI1WQY.jpg

https://i.imgur.com/nEACCcJ.jpg

The white stuff is spackle. I gave up on bondo. It’s hard enough. I have my friend, Bodyman Bill, or Bondo Billy, coming over to skim coat the entire helmet and smooth any rough stuff. It won’t be perfect, but it’ll be good enough for my purposes.

More updates to come.
 
Back with an update. The helmet has made it to “good enough for me” stage.

Today I cut in the arrows and the dent and then later, after this pic, the squares on the mandibles. I sprayed it and cooked it. Tomorrow I hope to sand it, then spray it with the blue. If everything goes REALLY well, I’ll hope to choose a mandible 2nd color and spray that also. But I’m trying not to get ahead of myself. Here was the helmet.

https://imgur.com/eiPVKcL

I have also made a pattern for the chest armor and cut it out of a trash can. Not bad for a first try!

https://imgur.com/sIWRARq

Anyone have any suggestions on the 2nd color for the helmet? Or how to make the shoulder armor? If I have time, I’ll be trying to make a pattern for it, and the bells, later tonight.

Thanks for looking!
 
I made the mistake of painting the helmet today. -5 outside, about 15 in the garage. Lots of problems even with my “heat booth”. A large cardboard box with a heater in it. Works great when it’s 20-30 outside. So my helmet looks a bit “shaggy”. I’m hoping it’ll be sandable to semi-smooth once it dries.

But because it’s so cold, heat forming the trash can armor took about 5 minutes. Heat, bend, instafreeze. Heat, bend, instafreeze.

I have to finish the rangefinder, but there’s just not very many pics of it.
 
For the life of me I couldn’t figure out what the problem with my armor was. It just looked way too tall. So I wanted to redo it. Turns out, I had the proportions correct too to bottom, but I was constraining it left to right.

After figuring it out, and going through the show to find a great reference image, I think I’m happy and can move forward.

Old armor:
https://imgur.com/sIWRARq

New reference image:
https://imgur.com/eDmDwfy

New armor:

https://imgur.com/ocFisU2

Have to do some sanding and it’ll be ready for paint. Just have to make the shoulder armor first.
 
Today I found a color I wanted to try on the helmet for the mandibles. It took me about 40 minutes to draw the mandibles then mask it. What a PITA. Here it is masked:

https://imgur.com/1guZvOP

Of course I was rushing, I want the helmet to be done so I can move on. Anyway, I skipped the step of spraying it with the light blue first to get into anywhere I missed. Turns out, I missed a lot. Ugh. Then when I tried to “fix” it, I made it worse. In the end, I’m going to have to spray the original color, wait, mask, then the mandible color again. I’d never had a mask job go so badly using the green 1/8” tape as a base. Really weird. Here are the pics before I tried to “fix” it. Good grief.

https://imgur.com/aXY3Fd3

https://imgur.com/Tlk3tal

https://imgur.com/DVAkwQL

In other words...I don’t think my costume will be ready by Wednesday. Lol.

I got my coveralls in today. I ordered what I thought was a light grey. Turns out. It’s just grey. It fit nice though.

Looking at the pictures, I should have gone with my first instinct which was a white jumpsuit. So I ordered white and am returning this one. Delays, delays.

I made a prototype of the shoulder armor out of cardboard. But I can’t find a trash can to tear up that is big enough. More looking tonight.

https://imgur.com/pr7iDsD

I ran out of 2mm cardboard, so the gauntlets will have to wait until I can get to hobby lobby. I wonder how big a PITA making them out of trash can would be? Anyone tried making them out of plastic then bending them to shape? Hmmmm....maybe I’ll give that a shot.
 
Okay. I think I’m finally done with painting the helmet. I just have to get a visor in there and some padding and be done.

My resin/fiberglass still feels soft in some spots. And it reeks. Can I brush on some hardener on the inside or should I make a whole small batch of resin with TOO MUCH hardener and recoat the inside? Or should I just paint the inside and that’ll make the resin smell go away when the paint hardens? What paint have you guys used in the past for the inside?

Pics. It took a LONG time to hand draw all the lines on the front. I think it gives the helmet a cartoony “drawn” look. Eh. I like it and that’s good enough for me.

https://imgur.com/27rmCJY
https://imgur.com/C1bzVOJ

https://imgur.com/U6QoDJs
https://imgur.com/TOuW1ra
 
Any suggestions on what/how to paint the inside of the helmet? I’m trying to kill the resin smell.

So today, I finally got fed up and cut out some “bad spots” in the fiberglass then glassed over nearly the entire interior. Then I painted resin with LOTS of hardened all over the interior. It seems to have worked pretty well. I still have a couple of “sticky” spots I must have missed near the edge. Anything to do about that? Any help is appreciated.

Moving along. I dull-coated the entire helmet. Everything is locked in now. I also cut the hole in the chest armor and painted the 3 chest armor pieces I have. Here are those pics.

https://imgur.com/ZK9nnyL

https://imgur.com/G4nyJHS

https://imgur.com/66by99Q

It’s starting to come together. Anyone know a cheaper, easier way to make the jet pack? I saw a build in here where someone pepped a jet pack. That sounds WAY easier than following WOF’s templates again. The last time I did it, well, let’s just say I’m still not completely finished. It’s been 3 years.

If anyone has the pep file for a jet pack I’d appreciate it. Thanks!
 
It’s been a weird year. Because of COVID, everyone is here at my house all the time. So I never really have time alone to work on projects. I am hoping to continue this build soon. Right after I get my Tusken approved.

I never did find a plastic piece to cut and mold to shape for the armor. So today, I resined the outside of the cardboard armor and am going to go from there. I hope to glass it sometime next week, then bondo, sand and paint. Then I’ll finish the gauntlets and it’ll be on to the jet pack. I really hope I can work on this a few days per week.

More pictures and progress to come. Hopefully.
 
It’s been a while. Life and parenting get in the way. Now that my kids don’t need me much anymore, I can finally get back to this build.

I have started the jetpack. I figure this will be a HARD re-introduction to this costume, and if I can scratch build the jetpack, the rest of the costume should be “easy”. (Well, easier I guess.)

I am using the WOF templates. In 5 years I haven’t found a way to get this done cheaper. Here is my start.

https://imgur.com/J9MHoZ3

I’m hoping to continue this build and get it “done” before spring.

Glad to be back.
 
I’m a little further along on the jetpack. Just have to find some cylinders that are the correct size for the tanks. I’ll get those in place, and the missile tube, then it’ll be on to resin and some smoothing with Bondo.

https://imgur.com/a3lfUtL

In the holiday special, there isn’t a lot of images of the jetpack. What I’ve done so far is likely overkill. I’ve got to mod a few things to match the screen grabs once I find the other tubes.
 
I knew the helmet and the jetpack were going to be the hardest parts, because everything on this version of Boba is custom.

I had a little more progress today. As you can see below, the canisters are spheres and the angle of the jetpack is like 18* going across the sphere at the top of the tank.

https://imgur.com/zE8WMfy

You can see the round tank tops in this picture from the front also.

https://imgur.com/xFYmcu9

After trying to figure it out, I finally decided on pickleballs to make the canister tops.

After cutting the edges of the jetpack to the correct angle, I inserted the pickleball and marked where the sphere would be showing. Then I cut the bottom off the pickleball and hot glued card stock from the inside so I can fill the holes.

https://imgur.com/vTslvI7

https://imgur.com/tXsiVHB

https://imgur.com/1ok0drf

I tried a couple of techniques to fill the holes. I didn’t like either so I’m sure I’ll have my day with resin and bondo.

https://imgur.com/GFV6EYv

Lastly, the jagged part that goes around the missile is custom. On a real Boba Fett there are 18 of the jagged parts. On Holiday Boba, it looks like 14 if you count the parts you can’t see.

https://imgur.com/9uQXcdy

So I did a ton of math and measuring, and while it’s not perfect, it does have 14 jagged parts.

https://imgur.com/WlVPhro

I cut it out of card board and mod podged it. Once I figure out the missile etc., I’ll glue it on and resin and bondo it.
 
I got a little more done on the jetpack before calling it quits. I added the top cover. I cut the backboard to the correct size and I cut the missile housing to the correct size. Just need the missile, the bottom caps, and the thrusters and it’ll be ready to get prepped into shape.

https://imgur.com/eIx72N9

I am going to be SO GLAD when this part is done.

Does anyone sell an accurate disintegrator ray gun? I’m kind of hoping I don’t have to build that also. I thought I saw Disney brought one out but I don’t know of the size or accuracy. Thanks.

Merry Christmas!
 
Another couple of days and it is slow going for sure. So many cones, so many circles. I finally have the “glade plug in” and the missile made. If I can just get all these parts built, I hope to fix them up with the resin and bondo. I almost can’t wait until that step.

But, if you want an accurate jetpack, it has to be scratch built. It’s not like any other jetpack.

Here is my progress.

https://imgur.com/QBRPfLL

I hope to get back at it next week.
 
While I’m here, I can’t seem to find a CRL for Holiday Fett. Is there one somewhere? If not, should I write one up along with this build? Would dented helmet handle the CRL or would it be TFE etc?

Thanks for any help.
 

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