Ord Mantell's ESB build

[Ord Mantell]

I started this ESB build in 2009, but for reasons out of my control, like never getting my original fully paid armor order from some feckless character calling himself 'Fettpride', among others, the project got put on hold.

My motivation for this build is different than my ROTJ. Because the ESB costume simply does not exist anymore, my goal is to try to resurrect that costume as a museum-quality build with as many vintage found parts, original techniques and vintage paints as possible to match the on-screen original as accurately and authentically as possible. The parts list below contains links like an index to the thread posts on those parts.

Parts list (updated May 1, 2025)​

lineage parts, vintage found parts, unconfirmed vintage found parts, original maker parts​

• Helmet - Minutefett ESB restored
• Helmet MQ-1 Circuit Board - vintage MQ-1 calculator board, version E10.
• Helmet interior electronics board - vintage found parts fully functional build of the original electronics
• Helmet Honeywell Micro Switch - vintage Honeywell micro switch, date stamped 1978 week 41
• Helmet Mulbrod cable clips - two vintage Mulbrod clips
• Helmet Runes - vintage Letraset Dry Transfer Font - Folio Bold Condensed
• Helmet Rangefinder - terminal fettler
• Helmet Rangefinder Red LED's - vintage correct 1970's Fairchild red LEDs
• Helmet Rangefinder Eye Piece - vintage polaroid SX-70 found part, correct version with angled lens
• Helmet Metal Ears - Elstree Precision Co., Limited Edition Re-Run Set #EPC15
• Helmet Metal Borden - Elstree Precision Co.
• Helmet Chin Straps with Chin Cup - Everoak Fully Detachable Harness vintage found part (new replica now available)
• Helmet Interior Harness - Foam. No longer using the Joe Brown harness as that likely wasn't in the helmet in 1979
• Helmet visor - smoked acrylic plexiglass sheet, heat-shaped in mold made from lineage helmet visor cast, Estreetplastics
• Bonnet/cowl - Clothears
• Armor - MinuteFett lineage + photogrammetry armor (paintup)
• Knee Darts - vintage Michell sweep arm part (cone) + MachineCraft (cylinders)
• Armor Collar Studs - possible vintage found part: Litton Royal 242PD adding machine keys, ebay
• Chest Armor Light Display - vintage found parts build in collaboration with Deancfh (how to install)
• Ab Armor Holes reflective backing - dental mirror, found part
• Ab Armor Speakers- vintage 8 ohm speakers made by Philips Weiner Radiowerke, Vienna Austria
• Jetpack - Bobby Fett UK from 2014.
• Jetpack Harness - Mojo Fett & Bobby Fett UK v2 screen accurate harness with four panel waist belt (2010)
• Jetpack Harness US Divers Belt Buckle - vintage found part, eBay
• Jetpack Beacon - MachineCraft
• Jetpack Beacon Lighting Kit - custom 6 volt bulb setup
• Jetpack Stabilizer - vintage J A Michell Engineering sweep arm base
• Jetpack Thruster Greeblies - Dark Side
• Jetpack Micro Mega Endodontic File - vintage red 90 (I'm not a believer in the blue dental file myth)
• Jetpack Hooks and Clips - full metal fett
• Jetpack Rocket - RafalFett 3D printable model
• Gauntlet Kit - MinuteFett photogrammetry gauntlets
• Left Gauntlet Glenross Dental Expander Screw - MinuteFett Glenross replica
• Left Gauntlet 'Laser' with Copper Tip - Elstree Precision Co., Limited Edition Re-Run #EPC29
• Left Gauntlet keypad - vintage MQ-1 calculator keypad.
• Left Gauntlet Flamethrower - ConvergenceProp's design for MinuteFett
• Gauntlet Micro Mega Endodontic Files - vintage red 45, silver 70
• Right Gauntlet Darts - vintage J A Michell Engineering sweep arm part (x4)
• Right Gauntlet Momentary Switches - vintage RS Components
• Right Gauntlet Ever Ready Minilight - vintage found part
• Right Gauntlet/Jetpack Cable Hookups - vintage ITT Cannon 5XLR made in the UK
• Right Gauntlet whipcord housing greeblie - model by Cantina Dude from the original gas lighter found part
• Right Gauntlet whipcord copper tip greeblie - vintage RS Electronics stripboard with 3.81mm pitch
• Right Gauntlet whipcord rod - MachineCraft replica
• Cape - vintage WW2/1942 US Army half shelter
• Wookie Scalps - made from scratch using nylon hair from Etsy
• Flak Vest - Clothears
• Flight Suit with neck seal (One Piece) - Clothears
• Hip Pouches - Clothears
• Gloves - Clothears
• Girth Belt - self-made recreation with correct mohair and vintage roller buckles
• Ammo Belt - white smooth vinyl from HandmadeHorrorShop on Etsy/TDH
• Sidearm Holster - vintage Nemrod holster, ebay
• Sidearm - vintage model Pulce 40, ebay
• Shin Tool Sonic Beam Weapon - vintage correct Paterson RC Print Squeegee 'type 2' with imprinted black logo (paint and build)
• Shin Tool Anti-Security Blade - vintage type 2 Paterson Squeegee +2 vintage J A Michell Engineering stylus brushes
• Shin Tool Survival Knife - vintage period correct Paterson Chemical Stirrer
• Shin Tool Mystery Tool - vintage karaoke microphone
• Boots - Imperial Boots size 11
• Boot Spikes - ConvergenceProp, limited run handmade highly accurate replicas specific to the ESB version
• ESB EE3 Blaster - Sidewinder (I sold my original vintage webley flare gun -- too heavy for my display)
• ESB EE3 Stock Greeblies - Unimax Safety Switch + Hirschmann LMK/AM Aerial Split Plugs
• ESB EE3 Blaster sling - ConvergenceProp

Okay, starting with the old Pulce 40 which was in storage for a decade. Going to do the holster while I'm at it.

Floquil 110601 is hard to come by anymore. Anybody know a good match for that old paint? Or better yet, anybody have any leftovers they don't need?

 

[ConvergenceProp]

Floquil Zinc Chromate Primer is the closest match I've been able to find to the original paint. Not sure if there's a new match for it made but I could post a color swatch if ya like

 

[sutt_hero_rotj]

Enjoy this project! It will be a fun one I’m sure. Eventually I’d love to do this one.

 

[Ord Mantell]

Floquil Zinc Chromate Primer is the closest match I've been able to find to the original paint. Not sure if there's a new match for it made but I could post a color swatch if ya like

Thanks. I do have a swatch. Just hoping someone knows of a decent out-of-the-bottle match before I go mixing colors.

 

[Ord Mantell]

 

[Ord Mantell]

With the local shops all shuttered, I took a chance at selecting paint on Amazon. Had to wait three weeks to get it and it was a fail. To my horror it has a faint metal fleck in it. And not the right color either. Certainly not what it looked like online. Does anyone know a brand/color that is correct or close to correct (besides the extinct floquil)?

 

[intwenothor]

Humbrol 100 is a reddish brown. You could try that or there's bound to be something in Vallejo.

 

[Ord Mantell]

Shin tools complete.

 

[Ord Mantell]

I got tired of the long wait to have paint shipped so I scrapped together tidbits of old paint and was able to mix my own color.

Okay, so don't do what I did and paint the whole tube. The backend fits into the plastic hand grip super snug so too much paint in that area will make it hard to get the tube back into place. I had to sand that part back down. Dangit. Don't do that.

reassembled...

weathered and completed. Pulce 40 no longer.

now I just have to finish the holster.

 

[Ord Mantell]

 

[Ord Mantell]

getting out all the bits and pieces in storage. I have no record where I bought any of this (most of it back in 2010). I don't remember the vendors. If you see your handywork in here, let me know. Unfortunately my MQ-1 and borden connector were stolen. Will have to replace those.

and here is the old Michell sweep arm for some of the doohickies. Is that the technical term? Oh, greeblies. Are these rare? I can't remember.

Time to break it up for the different destinations. Jetpack thingie, gauntlet dart, knee dart, and HIC control knob...

comparing the found part knee dart to a nice machined replica. Pretty solid match, but the original has a hollow point. Interestingly, the toe dart replicas I have do have the hollow point.

Also have this dental expansion screw piece. Unfortunately it's just a replica. It's a metal cast made by a friend who had an original. But still cool. He sent it in a replica box, too. Classy.

And I managed to get most of the armor trimmed, except for the chest pieces, and got most of the costume up on a temporary mannequin. This mannequin is 6'1", much too tall for Fett. The helmet and jetpack were both done 6 years ago. A lot of metal parts on those. Gaunts are on the way. Next task is to get the right mannequin and then get some paint and color where it's missing. Easy, right?

 

[droidbait]

Omg that Glenn Ross dental spacer!

Edit. Dang that is still a really nice replica.

 

[BudaFett]

Very nice work on the sidearm!

Reminds me that I need a metal expander.

 

[Ord Mantell]

So got a little distracted lately. My 70 lbs golden retriever puppy managed to somehow wedge himself behind my existing ROTJ costume display and knocked it over. Several things on it broke, so after my initial shock was over, I took it as an opportunity to fix a bunch of stuff I've been wanting to fix on it anyway. Of course, the list of things to do kept getting longer and it became a major project in it's own right.

Here's a pic of the pre-accident display. It's okay. Not bad.

Fettpride v2 armor. MoW gauntlets. Chris Bartlett's (aka TK-409) homemade flightsuit he used for trooping until he upgraded to a suit by Daz (aka Bobamaker). The flak vest is by Daz and the neckseal is by Mrs. TK-409. Woodman leather ammo belt. Jango Wes boots, etc.

So I wanted to change out the flightsuit, the flak vest, the neck seal to other versions I already had in storage, repaint the gauntlets because the original paintjob was too dark and purplish and always looked almost black in photos. The girth belt needed a re-dye to be more saturated. The gloves had faded so much over time they now looked all white, so they needed a re-color. The number of wookie braids is a little overboard. I had based those on the exhibits rather than the film, so I'm now more interested in matching the on-screen look, so take out anything not on screen. I also wanted to replace the fettpride shoulders with MinuteFett's new lineage shoulders, but the biggest thing was to change out the 6'1" mannequin with a shorter, proper height manny. Seemed like a manageable list. At first. But, boy, did it end up taking a lot of time.

The helmet is the one painted by Fettpride back in 2004 and was probably the first hyper-detailed ROTJ paintup ever done, and I can't imagine it's not one of the best ROTJ replicas in existence. The detail is just amazing. It must be seen in person to really appreciate it.

I have no idea what type of helmet it is. Fettpride remained coy about that. He never told me. I'm sure someone here knows. Best guess is Marrow Sun. It's big. Close to the correct movie helmet size. Thankfully the helmet was not damaged in the puppy disaster....

so I did a quick test-fit of on the new 5'10" manny to see if I could get a decent pose. I used a mannequin that had several busted joints that I ended up having to repair, so it gave me some issues getting the exact pose I wanted. At some point I will probably replace it, but for now it works.

I like the shorter stature. The proportions just feel better. Nothing else new yet except the tk-409 flak vest.

So now all the work. I had to add 're-color the flak vest and neck seal' to the list. I didn't really take any photos of the process, but the end results are a much better representation of the character than what it was before I think. I have to say I really like the lineage shoulders from MinuteFett. They are way better than the fan sculpts I've seen. Except there is a problem in the left shoulder, where on the middle corner on the front side is very soft and curled in. That's not exactly accurate. You have to heat gun it back into shape if you want it to look correct. I did an okay job. Probably could be better.

So DONE! Until the next disaster....

Now I can get back to the ESB display...

 

[Ord Mantell]

One more thing before I go back to posting ESB build progress. I had to create a new decal for the MinuteFett lineage shoulders. Since the decal outline is actually part of the cast, you can get the exact correct size the decal should be, which I did using evan4218's files from ages ago (Fett Chest and Shoulder Art Files).

For anybody interested in printing their own decals for their lineage shoulders, I've uploaded my adjusted file. You just have to print it out on vinyl inkjet printer paper and cut inside the solid black line. I made two versions in the same document 1) a clean version with white field and 2) a weathered version using exhibit photos of the emblem. I used the weathered version for the decal on my shoulders (above).

 

[Ord Mantell]

I feel pretty lucky to come back to this project at this magical time when all these amazing things are happening with lineage items. It's exciting. Finally! An ESB helmet that's the correct size and shape.

Trying to figure out a pose. My original inspiration for the pose was my favorite shot of Fett in ESB, outside the torture room:

I'll have to make updates to the wookie braids which are wrong. still need the gauntlets. several things to work on, but will get painting soon. I don't plan to use this new lid on this display. I want this to be strictly ESB so I'll be going with a cleaned up version that has only ESB production-era damage. Also the girth belt on this is too long. I need to find a shorter one. I'll put this one in the cargo hold soon for sale or trade.

Here's my ESB helmet journey:

On the left is my Don Post purchased in 1996, which I painted based on a single reference photo. In the middle is a 2014 FPH1 painted by Fettpride, and on the right is the new helmet of all helmets. It's HUGE, especially next to the pathetic DP. Absolutely beautiful. Like I said, it's an exciting time. They kind of look like Matryoshka dolls here.

Speaking of helmets, if you get one of the new lineage helmets, you should get one of these helmets, too:

*** edit - I must correct my earlier statement about the chincup in this helmet. My info was outdated. I had not seen intwenothor's exhaustive research thread on the ESB helmet interior until just now (intwenothor's accurate ESB interior thread.). The chin cup in the ski-doo has four holes where there should be three. But the interior attachments are still good if you are able to get a chin cup replacement.

 

[droidbait]

I feel pretty lucky to come back to this project at this magical time when all these amazing things are happening with lineage items. It's exciting. Finally! An ESB helmet that's the correct size and shape.

View attachment 192820

Trying to figure out a pose. My original inspiration for the pose was my favorite shot of Fett in ESB, outside the torture room:

View attachment 192821

View attachment 192822


View attachment 192823

I'll have to make updates to the wookie braids which are wrong. still need the gauntlets. several things to work on, but will get painting soon. I don't plan to use this new lid on this display. I want this to be strictly ESB so I'll be going with a cleaned up version that has only ESB production-era damage. Also the girth belt on this is too long. I need to find a shorter one. I'll put this one in the cargo hold soon for sale or trade.

Here's my ESB helmet journey:
View attachment 192824

On the left is my Don Post purchased in 1996, which I painted based on a single reference photo. In the middle is a 2014 FPH1 painted by Fettpride, and on the right is the new helmet of all helmets. It's HUGE, especially next to the pathetic DP. Absolutely beautiful. Like I said, it's an exciting time. I look forward to getting paint in this thing.

Speaking of helmets, if you get one of these new lineage helmets, you should get one of these helmets, too:

View attachment 192825

The vast majority of ppl here already know about this of course, but since I see that there still seems to be a market for replicas, thought I'd just mention that you can have a genuine one if you're patient. This one cost me $50 shipped on ebay. You get the chin cup, the strap and the leather covered attachments that go right into your new fett helmet without much trouble. vintage ski-doo.

View attachment 192826

Very nice! it also has the correct leather straps!

 

[Strider]

Wow, your RotJ display looks freaking amazing! Love how you replicated all the specific dirt stains.

 

[RafalFett]

I really like this pose (note that the image was colorized by me - I also used it as my avatar):

 

[Ord Mantell]

I really like this pose (note that the image was colorized by me - I also used it as my avatar):

I love that pose, too. Makes a great avatar. I have been thinking of going with a carbon chamber pose since it would pair better with my HIC. Nice colorizing job!