Merkava74's mannequin build

[merkava74]

So I decided to build my own mannequin for my Boba Fett costume, since the flight suit is going to be made to measure, and standard mannequins just won't cut it. The mannequin is going to have a PVC skeleton, covered by cling-wrap and duct tape, and filled with bean-bag foam pellets to keep the weight down. I have tried expanding foam, with disastrous results as the foam failed to dry I think because I sprayed too much too fast. Also, it did not fill out the carcass as nicely as I had wanted it to. Hence I went for the bean bag pellets route, which gave me more control.

Here is the skeleton template made out of PVC pipes and T-connectors. Simple straight connections except for the arms, which will be bent using heat gun:

 

[merkava74]

So the rules of duct-taping yourself are pretty simple:

1. Find someone YOU CAN TRUST COMPLETELY (In this case my wife);

2. Recall, before you begin, if you have any unresolved quarrels with her that might result in you being held ransom for new dresses or bags;

3. Do not, in any circumstance, start a new quarrel once the first duct tape goes on.

If the above 3 are fulfilled, you may begin:

1. Cling wrap your entire body, making sure no skin is exposed. Other forumners have used alternatives such as skin suits or old clothing. I prefer cling wrap as it best represents the actual contours of your body. Having said that, do bear in mind to do it fast, as your entire skin will not be able to breathe during this period. I would suggest doing this in an air-conditioned room so you don't perspire, and everyone is in a good and pleasant frame of mind.

 

[merkava74]

2. Next, the duct tape goes on. I found out that cutting strips is much neater than going round and round your body, as the latter will produce more creases. If you are suffering from OCD, then making sure you have sufficient tape of the same colour is paramount. If not, go crazy with the colours!

Here is the completed wrap. Note that blood circulation through your body at this stage is restricted. I have made a simple PVC blaster so that my hands can be taped in this posture. For modesty, I have photoshopped a helmet onto my face.

 

[Refugee]

Sweet. Duct tape mannequin build. I will watch with great interest..

 

[merkava74]

3. Next up, time to cut the wrap out. Do use a rounded point pair of scissors so that it doesn't cut into your skin. Remember that the cling-wrap and duct-tape are tight around skin, and you have very little manoeuvre space. This is the cut lines that I (my wife) made on the back:

And here's the cut-out carcass:

 

[merkava74]

4. The next step is to tape up the cut lines so that your carcass is whole again. I taped it up to the middle of the back so that I will have enough space to pour in my bean-bag pellets. The carcass is position over the PVC skeleton, and the ankles taped shut. Note that at this stage, I made a much sturdier base for the mannequin. This will be removed later. The bean-bag pellets are really easy to deal with. Pout them in, push them down, and pack them tight so that they fill up the shape of the carcass. Do this slowly, level by level so that each section gets as much pellets as it can. I also reinforced some areas with sponge. That is optional.

You can see that I have cut the arms out. This is CRUCIAL as with the arms attached, there is NO WAY to wear the flight suit. REMEMBER THIS STEP!

 

[merkava74]

This is what it looks like on the inside. I measure the lengths of the PVC pipes as I go along so that I can finally get the shoulder joints exactly where the arm holes are:

And the completely filled mannequin. I reinforced the shoulders with sponge. The arms will come later. It looks a little disproportionate, probably due to the angle of the photo:

 

[TheZeroEffect]

very cool so far

 

[merkava74]

Thanks TheZeroEffect!

The right arm is done, bent using a heat gun at the correct angle. I did not bother to fill the pipe with sand in order to achieve a smooth bend as this part will be wrapped with sponge. I have decided to wrap this with sponge instead of using the duct-tape arm and filling with bean bag pellets. Will provide more control and prevent any bursting of the seams in the future as the arms will come off and on several times.

Notice I had also shaved away some of the shoulder as the previous one made it look like a football player. I also added a chest (alas, I don't really have any) to give it shape. Beginning to understand more about the human anatomy through this build!

 

[Matty Matt]

Good idea with the rounded scissors. I scratched my arms up pretty bad when I did mine. Looking forward to seeing more. Looks great so far.

 

[merkava74]

Good idea with the rounded scissors. I scratched my arms up pretty bad when I did mine. Looking forward to seeing more. Looks great so far.

Hahaha! Matt, I am giving that advice AFTER I got cut a little too!

Ok so I moved on to make an articulated hand. Started with the right hand. Used wooden dowels, strung them up with steel wires, and attached them to a palm. Very tiring process, as each hand has 15 pieces excluding the palm. Turns out pretty well, very articulate, and stays in position:

Then I gloved them in a lady's stretchable glove, which makes it look even better:

As my Fett gloves are not here yet, I wanted to try the final look at the hand holding a trigger, and slipped it in my riding gloves. Looks good! But again, really tedious.

 

[merkava74]

Right arm wrapped with sponge, and hand attached:

Put him in a speedo, and I must say he does have the body of a swimmer!

 

[Refugee]

Wonderful. The build is coming along nicely

 

[merkava74]

Wonderful. The build is coming along nicely

Thanks! So many things to do, so little time!

 

[merkava74]

So after a little distraction (http://www.thedentedhelmet.com/f68/todds-sandman-boushh-helmet-build-52474/), I'm back to finish off my mannequin.

Bent the left arm, added foam meat to it, and gave it some clothes. I decided to give up on the home-made hands, and bought a pair of articulate hands from eBay instead. oh well.

So this completes my mannequin build, ready for all the parts to come together to make it a Boba!

 

[ROYSTERONE]

Great idea for a mannequin, might have to go down this route myself.

 

[merkava74]

Great idea for a mannequin, might have to go down this route myself.

It's really easy to do. Have fun!

 

[Nasedo]

I tried the Duct tape method. It didn't work out to well. :facepalm. My wife used pointed scissors and put a few slices in my arm. I threw in the towel, was to scared (We just watched Gone Girl). She feels so bad, so she just bought me a mannequin.:$. Love your pics. I tried.

 

[merkava74]

Hahaha! That Gone Girl part is hilarious!!