Welcome to TDH. You have come to the right place to get answers to all of your Fett related questions. Spend some time looking around and use the search function, and you should find what you are looking for.
With that said, I have a set of 1/8" thick aluminum plate armor that I am very happy with. However, the collar piece of my set was too small for overly muscular and broad shoulders. JK
But really, my collar piece was to small for my frame, so I decided to try my hand some metal work.
I used my existing small collar piece to make a poster board template, which I drew larger, cut out and tested on my chest / shoulder area. I then transfered the template to a piece of 1/8" aluminum plate I picked up from a local metal distributor. I cut the piece out of the plate, and taking a que from
American Chopper I bought a pannel beater bag and mallet, which I used to shape the armor. I added the dents using the mallet and a some cold chisles, roughed the surface with my orbital sander, and presto ... collar armor that fits.
I am working on making a back plate from scratch, to match up with my collar armor. I will post some mor pictures as I make some progress.
Gator