Thanks for helping me out and making a new set of templates Wizardofflight!
I think the greatest part of making this costume for my son is that he is so excited about Star Wars, and he got that way without (much) prodding from me. He has a friend in town who is into the series, and it has just taken off... movies, video games, and now the costume.
I asked him what he wanted to be for Halloween this year. He was "Elvis" last year, dont know where he got that idea, but I assumed it would be something strange again this year. He said a stormtrooper. I thought cool, and started some internet research into costumes. I found some sites on costume building, and decided to go to Boba Fett instead, but build him a nice set instead of buy some premade thing. I did not tell him, figuring I could surprise him later. He tells a couple days ago that he changed his mind, and would really prefer to be Boba Fett. I have no idea how that happened, I didnt tell him what my plans were.
So I am building the trash can armor set for him, and going to try to scratchbuild a helmet. We will see how things go from there. I still have not told him I am doing it, I will be working on it after he goes to bed at night and when he is at school. I think he is going to be very surprised... and if it turns out nice, it will be like Christmas to me, watching his expression as he gets what he wanted all along. The simple things, right?
The hard part is getting things sized to him, without him realizing what I am doing.