General Wizardofflight Armor Template Tutorial

Sintel

New Hunter
Hi everyone,

This is my build of Empire strikes back Boba Fett armor using Wizardofflight's templates.For this I will be using 5mm and 2mm PVC foam-board, Foamalux http://www.brettmartin.com/en-gb/plastic-sheets/products/foam-pvc.aspx
As I progress through the build I will be adding tips and any unforseen problems that occurred during the build.I am doing the Chest , Backplate , Shoulder plates , Gauntlets , Cod piece and Knee pads. I am also doing the jetpack as well. but will be the last item on the build.
All the templates I found in one place Boba Fett Costume Guide - Fettpedia - Boba Fett Fan Club .If you don't want to leave TDH they are here http://www.thedentedhelmet.com/f20/all-boba-fett-armor-stencils-templates-23196/ just check if the size is right for you. I am 5,6 or 173cms but with a wide chest so I went for the 5,9 tall chest armor. I would stick to this site for all color reference and how to or finding items as this site is the great repository of all things Fett have fun enjoy and I hope this helps some to get started.

Also here is the link to my helmet paint thread for Mr Fett. http://www.thedentedhelmet.com/showthread.php?t=53991
 
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Sintel

New Hunter
First I cut the template patterns then using double sided tape stuck them to the plastic protected side for easy removal. After cutting out I sprayed a light mist of paint to show the edges better.
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Get a good quality box cutter or hobby knife as comfort when cutting is essential. Metal rulers are good for keeping lines straight when cutting and a rotary tool with a sanding drum to do the round lines and edges,
* TIP 1 when cutting out parts like belts or gauntlets cut the lengths beyond the templates to ensure the right size and give extra to work with nothing worse than being too small by a centimeter or 1/4 inch
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Armor plates: Once cut need to be formed using heat gun and gloves. (unless you have no nerves or are a lava person) heres a link to "Mando Smith" youtube. tutorial https://www.youtube.com/channel/UCTIXn1YIQU1o2_-y7DoGR0A
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Backplate: You need a dummy or a friend when doing the backplate and collar to get the bends right to sit on the shoulders.
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For the Cod piece I used the three templates the bottom is 5mm PVC Foam-board the middle is 2mm and the top is 5mm to do the dent I heated the section for it slowly then used the head/handle of a file to imprint a round divot while supporting from the underside. I just used 5mmfor the two buttons on the left side and cut them on the angle.
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Knee pads: coming soon
Gauntlets: coming soon (for the 3rd time lol) [1st Started left gauntlet as first go using PVC fb bit small on the arm and a bit imprecise on the cuts] [ 2nd restart learning from mistakes the ones you see now all 5mm] [3rd try will mix 2mm and 5 mm to get it closer to right lines.]
Jetpack: Done but going to list last just to make you suffer lol.
 
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Sintel

New Hunter
This section will be for the bogging and painting of all parts including fitting of other finishing touches.

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Sintel

New Hunter
`I have a 2000 watt heat gun so the low setting was great to get the heat in but not cook (high will burn btw all I say is test it) the rockets on the jetpack (coming soon to the post) are the hardest but I will show how I did it.
 
No easy task, you have made a good job of that... How easy was it to manipulate the PVC ?
It's easier to manipulate the PVC foamboard he is using here than regular PVC. Ive made sets of armor out of multiple materials (PVC pipe, sintra, aluminum, fiberglass, etc) and I'll say that this Sintra is one of the best to work with regarding Fett armor.

Its malliable when hot, easy to form, and is extremely rigid when cooled. Very pleasant material to work with when doing armor.
 

Silverstalker

Active Hunter
I would like to get my hands on his stuff and have a go at it, but ''Sintra'' as its known in the states seems to be a hard thing to get hold of, and no matter how much I search for it all I get in comparison is like some horrid packing foam stuff....

just cant seem to find it...... either way its looking great. (y)
 
I would like to get my hands on his stuff and have a go at it, but ''Sintra'' as its known in the states seems to be a hard thing to get hold of, and no matter how much I search for it all I get in comparison is like some horrid packing foam stuff....

just cant seem to find it...... either way its looking great. (y)
I created a tutorial last year on making Fett armor out of PVC Pipe from the local hardware store. Check it out of you want or need to:)
https://r.tapatalk.com/shareLink?ur...6&share_tid=56166&share_fid=9313&share_type=t
PVC Pipe Fett Armor

I also used Wizard of Flights templates for this build.
 

Sintel

New Hunter
I would like to get my hands on his stuff and have a go at it, but ''Sintra'' as its known in the states seems to be a hard thing to get hold of, and no matter how much I search for it all I get in comparison is like some horrid packing foam stuff....

just cant seem to find it...... either way its looking great. (y)

Just look for wholesalers of pvc foamboard.or go to local sign makers as they use it for printing display signs.
 

Silverstalker

Active Hunter
yeah foam board here has a totally different meaning and you end up with with a sheet of 'foam' like hollow air bubble stuff....can bend it with your little finger, I think I have the correct stuff in my stores '' a no smoking sign'' I will take it down to a sign makers and as ask them what the heck we call it here other than ''foam board, Sintra etc....
 

Sintel

New Hunter
I would like to get my hands on his stuff and have a go at it, but ''Sintra'' as its known in the states seems to be a hard thing to get hold of, and no matter how much I search for it all I get in comparison is like some horrid packing foam stuff....

just cant seem to find it...... either way its looking great. (y)
Well here's a link to the manufacturer for foamalux (sintra) I have no idea what quantities they would require but might point to a local source. http://www.brettmartin.com/en-gb/plastic-sheets/products/foam-pvc.aspx
 

Sintel

New Hunter
OK I have completed the Jetpack as well but found it hard to make the rocket look any good so I bought a 3D printer and used Rafs 3D models to print it. I was also able to get the other parts and print them.

Gun and Gauntlets and shin tools I also had to model the attachment bit for the right gauntlet where the pipe from the shoulder mounts.
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Test fitted the gun together then used putty primer on all the prints and sanded till they were smooth.


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The Rocket print worked well with the grapple prongs fitting and being movable I tested the chroming with molotow and used the same for the blaster barrel.
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Painted the foamboard parts but re-did the knee pads as they broke should have re-enforced with a bit of fiberglass sheet so I 3d printed new ones.

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And after a bit of trial by error I found a spray can color that was a close match to the jetpack color and finished that. Had to reprint the beacon as that broke the top off :-( . see below for first outing with a good mate at Perths Supernova convention.
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Still need to work on the jetpack harness so it sits right and a few other little things.

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The boots were wrong in this photo as the replacements hadn't arrived.
 
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