General Short Boba Fett build for Halloween

Got the armor mocked up on the flak vest, should be a good fit for her. Bad news is the polyester flight suit failed on the color removing journey. I used Rit Dye color remover but all it did was make it a lighter shade of green. 4 packets and then bleach later on and nothing...a bit too late to redo another suit or custom make one so sadly, the suit may be a different shade off, not like the folks at her company will notice, but disappointing. I'd like to at least try to get it a darker shade or gray/blue to contrast the armor instead of all green. Lesson learned, don't try to color strip a Rubies costume suit.
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Moving on, I had a few folks message me about 3d printers and I've become a go to person on the subject for my local 501st garrison. I am still new to modeling but luckily most of the models are very simplistic for the Fett gear. I'm a huge advocate of Fusion 360 and Sketchup (though the older version is nicer) but I also really push Tinkercad, a browser based modeling program for folks who are new to it and want simple things made. First example, the buttons on the ROTJ flamethrower gauntlets. Modeled it up in tinkercad and took all of 10 minutes and a set of calipers. I'll be starting on the gauntlets more tomorrow and printing out the buttons to add on them. Fettpride never included the greeblies or molds for them so I'm starting from scratch on them, first simple version of the front calc. keypad and a new one I did today with notches and a slight detail at the edge though not noticeable at the scale. Also made a small dental expander that isn't 100% accurate but it works and is sized correctly for the gauntlet. Added some reference shots with one circled in orange to show the buttons. Chest emblem paint templates are cut out and will start painting on them tomorrow. Flightsuit is leaving me down but definitely wont halt this build.
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Wow Very Nice !! You're making good headway on everything !! I'm wondering if you could just shoot the flight suit with a water based paint to get
a different color on it?? I'm sure it would need to be fairly dark to cover the green, but it would be better than green...
 
Wow Very Nice !! You're making good headway on everything !! I'm wondering if you could just shoot the flight suit with a water based paint to get
a different color on it?? I'm sure it would need to be fairly dark to cover the green, but it would be better than green...
Yep, I'm going to try just that. Even if it gets to be a dark gray, it'd be better than green. Once we have more time, we'll just be doing a custom made flightsuit all together.
 
Update on the flightsuit. This is what it looks like after a wash and dry cycle...some color removed but not much. Going to try to dye it gray either way and see what I get. Scrap shot next to it for a comparison.
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Cleaning up the dental expanders, added a backing to them to print so I would not have to use any supports, just snap it off with a knife or scraper and you're good to go.
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I'm tired of sanding so thought I'd do a bit of acetone smoothing. Rocket went well, same with dental expander but I guess the keypad was still too soft...wrecked it and had to restart another. Using my fancy laboratory setup to cold acetone smooth the gauntlet pieces.
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Here are some shots to compare a raw ABS print to an acetone smoothed version. Lost some sharpness but I'm fine with that with the time savings.
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This is so amazing!!!
I am completely new to the cosplay world and have been searching for a way to be Boba Fett. I never realized how difficult and expensive it would be, especially since I am not creative and cannot make anything myself.
I was so excited to finally see that something has been made for someone my size and it isn't for a child!
I'm a little under 5 feet tall :(. I really love what you've created for your sister and was wondering if you're planning to sell it after she's done with it or if you plan to make more at all? If so, please keep me in mind! :) Thank you for sharing your journey also! The end result is just breathtaking.
 
Incoming photo dump, my desktop sadly crashed and imgur decided to crud out on me but finally got some photos. I'll add details soon but the build was completed and a lot of fun. Works been a pain but some shots from the halloween party make it all worth it.

Dirtied it up so it would stand out in shots more, base paint job done by Raizo/Alex Lane, weathered it, cut out and added in the welding visor to replace the rubies junk, extended stalk made and sold by me.
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Cheap $10 target backpack converted to a harness
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I had a belt that was too small for me, the belt boxes had wooden blocks in them that weighed about 1.5 oz each one. 3d printed a hollow PETG version that weighed .3 oz each box and replaced them.
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And we are done! Photos edited for privacy. To get an idea, my sister's friend in the witch costume is 5 foot 3.
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She's a hipster chick working in the SF in CA in the video game industry, the boba tea photo was a given.
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Total build time, approximately 3 weeks.
 
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