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Boba Fett Costume

Step-by-Step Boba Fett and Mando Costume Guide

Torso

Tips from the Pros

Under Clothes

  • Jump Suit (Grey or VERY Light Grayish Blue). COST: $50-70
    Available at Army Surplus stores. This helmet is simpler than the one you saw in the films, but it does the job.
  • Turtle Neck (Same color schemes). COST: $20-40

The Armor

  • Sheet Metal. COST: Price Will Vary
    Available at hardware stores.
  • Instructions:
    (I used Galvanized Steel for mine.) First you need to cut the Sheet Metal. I used Tin Snips and a friends help to cut out the seven pieces for the armor. The seven pieces are: the four pieces of the chest plate, the neck to over the shoulder piece, and the two arm/shoulder pads. All you need is to look at different pictures of the armor right here in The Vault and make your own patterns to fit your size. *You can also make the chest piece into one piece for ease of wear.* Once you get all the pieces cut out take a ballpeen Hammer to it for those nice worn in dents...

    CAUTION!: Metal can be SHARP be sure you file down the edges!

    Tips From The Pros: Flynn O'Connor
    Use rolled aluminum instead of steel. It's cheaper, easier to cut and shape, but just as sturdy. Also holds paint quite a bit better while retaining that "real metal look." Also, you can actually scratch the paint off and the aluminum, being made of different silver shades, looks pretty banged up.

    Use the aluminum over cardboard. Cardboard is obviously easier to cut and shape, to get the right shape down, then cut down the aluminum to the approximate shape and actually "fold" the aluminum edges around the cardboard, thus using the easily cut edges of the cardboard. Also, since you are folding the aluminum and crimping it against the cardboard, it's easy to put a strap in the fold so that the piece of aluminum can be work tight against the body.

    Electricals. Don't be afraid to try and bring a little light to your costume. All versions of my outfit (I'm up to about version 5). Have had the light-up chestplate. Battery-powered Christmas lights, under a colored gel that fits in a hole cut in the chestplate is an effective method. Other methods I have tried: I reverse-engineered a street hazard light (the blinking ones) and had that rigged up for a while. The blinking effect was kinda cool...(but highly illegal). The best electrical unit was off a generic "space gi-joe" or something on the Toys R us value rack that had a little light up blaster rigged to a watch-battery powered pack. That works nicely, and that way I don't have to lug around "D" cell batteries anymore. Still trying to rig up a cost-effective PA/Amplification unit.

The Cape

  • Cloth Cut Out (Make your own). COST: $4
  • Instructions:
    Cut out a cape and attach it to the left shoulder of the neck piece and use velcro to attach it to the right.

Forearm Units

  • Plastic Shin Guards and Add-ons. COST: $10-20
  • Instructions:
    Take the Plastic Shin Guards and paint them: Red, Moss Green, Yellow... Whatever version you want to make. Then, You can cut the barrels off of some toy guns and paint them black. When they are dry you can Hot Glue them onto the Shin Guards(forearm units). A Credit Card Pocket Calculator painted Moss Green and Hot Glued onto the front of the left forearm unit can also be added for a good computer console pad effect. You can then run tubing from the back of the gun up the sleeve and under a flap of fabric that can be sewn onto the Jumpsuit.

    Tips From The Pros: Flynn O'Connor
    Look everywhere! Since Fett's costume is made of so many odds and ends, it's hard to say where it all comes from, but keep your eyes open wherever you go. Pieces of clear vacuum-formed plastic for toys, hardware supplies, etc. have interesting shapes that look realistic on the gauntlets and kneepads... lots of little curves and shapes. My gauntlets have bits of a hair trimmer package cut, glued and painted to get the right "flame thrower" shape.

Gloves

  • White Gloves. COST: $5-15
    I used a pair of white gloves with two football handpads (Painted Moss Green) to complete the handwear.

Accessories

  • Wookie pelts. COST: $2-7

    Tips From The Pros: Flynn O'Connor
    Use pre-braided doll hair.

EE-3 Blaster

  • No. 1 Mark 1 Military Signal Gun manufacturered by Webley & Scott (England) was the basis for the actual prop in the film.
  • Toy Blaster. COST: $20-200

    Tips From The Pros: Flynn O'Connor
    Ok, so I don't have a great blaster. But then again, when I go places in this thing, (like Halloween) it's often in bars that make me keep it outside anyway. So I haven't even tried to get a good blaster for a while.

 

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