General Short Boba Fett build for Halloween

shenphong

Hunter
A few folks here have known that I am the current owner of the FP Fem Fett molds with the 3/4 size jetpack and have owned them for a few years now without doing much with them. Goal was to make a costume for my wife but sadly life got in the way and that got pushed back after a few moves. Finally, I got a good reason to yank the molds out and start producing something as well as changing and replacing a few things. I ended up getting these after someone picked them up for a Fem Fett build themselves and it not working out. Goal is to make a small Fett build for my sister who is 5 foot 1" in 2.5 weeks and an employee at a major video game company with a really large costume contest and prize. Started to pull some plastic and began converting one of the chest plates to a more "standard" Boba Fett chest plate for vacuum forming.

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While working on the chest pieces, I continued working on the ready plastic pieces. Sanding, trimming, and priming.
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A lot of foam, wood filler, bondo, styrene and cardboard and I started to get the new chest plates looking like how I wanted them.
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Plaster and rubber and now I have my new vac form chest plate molds. Success on the first try, pulled in .125" HIPS, trimmed and sanded in the photo
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shenphong

Hunter
Painting...this is not a screen accurate paint job, but with the job of fabricating these and prepping my own costume for Halloween + a few other commissions within a span of 2 weeks, this will have to be close enough. I'll go back and improve on the paint job later on. Paint was done using Krylon spray cans suggested by members here(man I like these much better than rustoleum, such faster dry times).
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I ended up mocking up some "shrunken" greeblies via fusion 360, extremely basic and very easy to use especially with the photos and models on this site used for references, thanks to folks like rafalfett and wizardoflight! It just looks better with scaled greeblies vs using full sized bits for the jetpack and knees.
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The FP gauntlets did not come with a bottom piece which I will mock up, but the whipchord housing also was just a miniature ESB version. I thought I'd model up a ROTJ version that I'll release publicly though not sure I'll get it done in time for the costume build.
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shenphong

Hunter
Thanks! You know it. Sat on these for the last couple of years and figure it was about time to start playing with them and seeing what others thought.
 

shenphong

Hunter
I'm lucky enough that though I'm short on space where I currently live, I have a plethora of equipment at my disposal. One of those? A vinyl cutter. Opted to make my own paint decals, thanks to my wife as a graphic/visual designer for mocking these templates up then off to the cutter for paint templates. Shoulders first and chest coming very soon, a bit too clean at the moment but it works!
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hvacdon

Hunter
Really Sharp Looking !! I'm anxious to see the next set of progress pics !! Are you planning to go into production with this kit sometime in the future?
 

shenphong

Hunter
Thanks! Possibly, at this point I've offered to assist some of the folks who had orders like the jetpack, from FP and never fulfilled them. That's about the extent of it though goal is to start making limited runs of these, separate parts or whole costumes. My main job just gets in the way.
 

shenphong

Hunter
Made some gauntlet top pulls, top is a bit sharper than the bottom gauntlet, my heating element is a bit weaker there...gotta fix that in the future. I still need to make new bottoms but may go with a very basic design for this costume since I really need to focus on my own build. But the tops are done and greeblies coming soon.
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Started working on the chest plates using krylon olive green and hunter green spray cans. Trimmed out the chest lights display, sadly all of my tools are at my main shop so made due with a dingy x-acto knife and sanding sticks. Should of gotten some more cutting discs for my dremel! Added some dents and dings with the sanding drum.
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shenphong

Hunter
For the flight suit, we picked up a size S rubies top gun costume that my wife is altering. Goal is to bleach it, color remove it and dye it gray. Even at size S, its far too big for my 5 ft 1" sister BUT that is going to be a big help. Will get some updated shots of it during the day, but we've successfully cut down the legs, reused that material for the sleeves of the flight suit and used some of the extra material for faux pouches on the leg.
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hvacdon

Hunter
Well that's cool. At least that makes it a little better!! If I mentioned 3D printing at my job the response I would get would be 3 what ??
 

shenphong

Hunter
Working on the jetpack that I cast myself, created a new mounting setup for the thruster and the main pack. Had my wife model it up per my measurements and it works! Uses a m5 bolt and you can use a nut with it or wingnut for attachment inside the pack. Insert the bolt, add glue/epoxy, place in the thruster, drill hole into the pack and install. yes I have the thruster bell reversed, drilled the wrong side but it works for the photo. yes I also have the wrong rotj color scheme for the pack, since most folks won't realize at my sister's company and I'm short on time, figured I'd go with the ESB paint vs ROTJ. ROTJ will come later but jeezes too much masking for now.
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shenphong

Hunter
blaster is a hasbro blaster. sanded all the text off of it, primed and painted with krylon flat black, then added acrylics to weather like the MR version I had before, just less markerish paintjob. Lights and sound still work!
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shenphong

Hunter
Custom flightsuit for my 5 foot 1 sister, wife converted a rubies top gun small mens costume into something close...hemmed the legs, used the extra material for the added shoulder sleeves and prepping for redying soon. Added a shot of the original to compare.
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