Welcome to my WIP - it's an ongoing thread and a record of how I built the following male and female kits for myself and my Disney-obsessed wife, Jayne, in just over 12 months and got them passed as official kits in time for Star Wars Celebration 2016.
Both kits, total cost no more than £200GBP to make. Everything was built from the cheapest raw materials and objects found in the recycling. Only Jayne's under armour, my overalls, boots and the two skate helmets used as a basis for our helmets were purchased.
(http://i.imgur.com/pEFIyma.jpg)
(The mouse ears on Jayne's kit are just for fun and are easily removable!)
To allow me to easily reference my WIP here's a table of bookmarks that I'm building to skip to the relevant sections.
TABLE OF CONTENTS
Note - sometimes a post covers several topics so you may have to scroll down a little to find the exact info you're looking for within the post
JULY 2017 - APOLOGIES FOR BROKEN IMAGE LINKS - CURRENTLY RESTORING THEM AFTER MOVING OVER TO IMGUR FROM PHOTOBUCKET - IF YOU HAVE ANY QUESTIONS, PLEASE PM ME AND I'LL DO MY BEST TO RESTORE THE RELEVANT IMAGES FOR YOU ASAP
Helmet - sizing paper template to head (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1372450#msg1372450)
Helmet - making cardboard form to shape Foamex to helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1373071#msg1373071)
Helmet - shaping Foamex around cardboard form (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1378117#msg1378117)
Helmet - attaching Foamex wrap to skate helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1387690#msg1387690)
Helmet - heat forming cheeks and attaching to mandibles (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1396888#msg1396888)
Helmet - earcap scratch build from BBQ sauce lids (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1404116#msg1404116)
Helmet - earcap body Foamex scratch build and attachment to helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1424957#msg1424957)
Helmet - welding T-visor cutting and attachment to helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1424957#msg1424957)
Helmet - smoked acrylic T-visor cutting (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1781411#msg1781411)
Helmets Version 2.0 - Screen accurate Boba Pepakura/Pasteboard build, mould and casting (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1742656#msg1742656)
Chest Armour - how to trim down to fit (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1481376#msg1481376)
Chest Armour - Boba-style display from an old iPod (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1501113#msg1501113)
Chest Armour (female) - darted chest plates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1541616#msg1541616)
Gauntlets - how to build forming jigs using WoF templates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1517273#msg1517273)
Gauntlets - scratch build from WoF heat-forming over cardboard jigs (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1436883#msg1436883)
Gauntlets - Digital Photo Frame installation (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1447131#msg1447131)
Gauntlets - LED lights for longer lasting 'scanner' upgrade (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1669340#msg1669340)
Gauntlets (female) - scratchbuild from WoF heat-forming over cardboard jigs (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1448398#msg1448398)
Gauntlets - scratch build missile from chop stick & PVC pipe (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1456760#msg1456760)
Gauntlets - simulated paint damage using masking fluid, hairspray and rock salt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1524139#msg1524139)
Knees - scratch build using WoF templates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1458580#msg1458580)
Knees - heat forming tips & using cardboard jigs (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1458978#msg1458978)
Knees - assembly and shaping side blocks (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Knees - strengthening WoF knees with PVC strips (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1476357#msg1476357)
Knees - simulated paint damage using masking fluid, hairspray and rock salt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1527334#msg1527334)
Knees - attaching with sleeved elastic strapping (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1537696#msg1537696)
Knees - upgrade - Velcro + strapping adjustment for more comfort (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1738018)
Cod Plate - from WoF template (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Cod & Kidney Plates - attaching using snaps and an old webbing belt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1496116#msg1496116)
Shoulder Bells - from WoF template and how to heat form (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Shoulder Pauldrons (female) - bulking out shoulders to balance a larger helmet (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1555606#msg1555606)
Boots - UK supplier (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1425906#msg1425906)
Boots - armour attachment (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1509867#msg1509867)
Ammo Belt - cardboard forms for Ammo Pouches + Template Files (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1447131#msg1447131)
Ammo Belt - magnetic closures and wrapping with pleather (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Ammo Belt - flaps (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1476357#msg1476357)
Ammo Belt - belt from old belt, cereal box card & pleather (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1480157#msg1480157)
Girth Belt - sewing smaller strips of paracord before combining them into a full belt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1509867#msg1509867)
Girth Belt - using paracord, card, gaffer tape and pleather (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1519140#msg1519140)
Flak Vest (male) - making with own template (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1480157#msg1480157)
Flak Vest (female) - making with own template, chest darts (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1536885#msg1536885)
Flight Suit - simulating grime and dirt with acrylic paints (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1580247#msg1580247)
Rifle Sling - using a 3-point sling to make carrying carbine-style weapons easier (http://mandalorianmercs.org/forum/index.php?topic=95388.msg1612324#msg1612324)
Sanding Tips
Sanding tips - wet & dry sanding and using different grits (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1404116#msg1404116)
Heat Forming Tips
Heat forming tips and using cardboard jigs - quick and easy way to get perfect curves (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1458978#msg1458978)
Cardboard jigs - how to make them fast (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1472053#msg1472053)
Using aluminium foil & heat to create convincing physical damage (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1491864#msg1491864)
How to "Roll" the edges of armour plates (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1526620#msg1526620)
Using Snaps
How to attach plates using Snaps...and still make adjustments afterwards! (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1536946#msg1536946)
Painting Tips
Masking straight lines over curved surfaces using an elastic band (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1572300#msg1572300)
Simulated paint weathering techniques using masking fluid and rock salt (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1578642#msg1578642)
Using scrunched Aluminium Foil for masking removal (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1703309#msg1703309)
Espresso coffee use as an effective dirt wash (http://mandalorianmercs.org/forum/index.php?topic=100143.0)
Using Aluminium Tape to make things look like real metal (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1703309#msg1703309)
Weapons
Build Log: 1313 Inspired Blaster Carbine using Foamex, MDF & PVC Pipe (http://mandalorianmercs.org/forum/index.php?topic=95388.0)
(http://i.imgur.com/Jqqe4ll.jpg)
Build Log: Twin Westars from WoF templates using Foamex, MDF & PVC Pipe (http://mandalorianmercs.org/forum/index.php?topic=94201.0)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_3879_zps8fdn1dmk.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_3879_zps8fdn1dmk.jpg.html)
Build Log: Kal Dagger build using Foamex & PVC Pipe with downloadable template (http://mandalorianmercs.org/forum/index.php?topic=100143.0)
(http://i725.photobucket.com/albums/ww258/simorph/Kal%20Dagger/IMG_3883_zpsnvjp7ilt.jpg) (http://s725.photobucket.com/user/simorph/media/Kal%20Dagger/IMG_3883_zpsnvjp7ilt.jpg.html)
Build Log: Sidearm Scratchbuild using MDF & PVC Pipe (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1669340#msg1669340)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_0918_zpsss0e4igz.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_0918_zpsss0e4igz.jpg.html)
Build Log: Vibrosword Scratchbuild using MDF, PVC rods & Aluminium Tape (http://mandalorianmercs.org/forum/index.php?topic=93907.msg1693448#msg1693448)
(http://i725.photobucket.com/albums/ww258/simorph/IMG_1022_zpsbmhou2tv.jpg) (http://s725.photobucket.com/user/simorph/media/IMG_1022_zpsbmhou2tv.jpg.html)
And here's the start of the thread as it was when I first posted to it on Jun 10, 2015, 02:10 PM :
Jayne & I have been discussing colours - she really likes the idea of a Zam Wesell palette of purples, greens and golds and wants to go for black form-fitting underarmour gear as her bodysuit to keep things feminine.
I on the other hand, have been thinking much more down-and-dirty for my gear, and having studied a lot of Star Wars reference decided to work with all those earth tones you see throughout the movies, especially on the bounty hunters in Ep V.
To that end, I've already purchased a flight suit - an Armoured Fighting Vehicle coverall and using that as a base:
(http://i.ebayimg.com/22/!BVsMY(wB2k~$(KGrHgoOKi4EjlLm,WWnBKT0nH)fCQ~~_12.JPG)
(http://www.ebay.co.uk/itm/Army-Surplus-ARMOURED-FIGHTING-VEHICLE-COVERALL-Medium/270420621597?_trksid=p3693.c100102.m2452&_trkparms=ao%3D1%26asc%3D20140212121249%26meid%3Dac060046a2914f5e86f584a4a6bcd53a%26pid%3D100102%26)
It cost me £15 GBP + postage and arrived brand new, fit great and has plenty of 'real world details' that mostly will be covered with armour pieces but should give it more interest than making my own gear.
There are some cool pockets on the front of both thighs and shins that I may have to remove, but I'll make that decision as we move ahead - but certainly comparing it to the movie Boba flight it feels pretty close to me.
That done, I've nabbed the outlines from the online resources and set about with Photoshop to come up with these two designs (I used Photoshop because it allowed me to drop a suggestion of the amount of weathering as well as smaller details on the helmet. etc):
(http://i.imgur.com/mV5r5wy.jpg)
Trying to come up with something that will incorporate some of the purples and greens that will appear on Jayne's gear but will give me the kind of functional, heavily weathered Boba Fett bounty hunter feel that wouldn't look out of place walking through the background of Mos Eisley in any of the movies - just enough customisation and differences in colour to get the look, but steering away from something that looks too outlandish or ceremonial.
Currently pondering whether to go for longer armour plated riding boots, or smaller armoured boots like Jango with additional cloth spats at the ankles to reign in the bottom of the flight suit (as they do on the Boba suit) but cover the boot tops/ankles.
Going for skate helmet-based builds for the buckets - will start building a cardboard mockup/template to test before I start cutting the real Foamex(Sintra) ones.
Thoughts/advice/preferences/suggestions anyone?
Thanks
Well, I thought I'd better drop a line to let you know how it all went in the end.
Technical stuff first:
- No kit failures on either kit, save for one ammo pouch came loose on Jayne's ammo belt so we had to re-stick it at the hotel
- The iPod chest display worked a treat - lasted for hours and hours and didn't run out of power
- Digital frames in the gauntlets automatically turn off after about 5 minutes so will seek a better solution for that some time
- Turning the carbine gun sling into a three point sling was the best decision I could've ever made - I never had to bother about carrying the blaster around or dealing with the weight of it
- Thankfully my gloves were able to operate a touchscreen while on, Jayne had to remove her gloves to operate a smart phone - think about that one in advance folks!
- My gaunts held up fine but rested on the backs of my thumbs - after only a few hours of wearing them I found the backs of my thumbs had gone weirdly numb - the feeling has just about worn off some two weeks later - but I'm thinking of installing some Velcro inside the gauntlets to take the weight in future
- Helmet fans for the win - perfect for staying in kit for hours, just enough breeze and virtually no noise - the power pack lasted for as long as I was in kit so pairing up 2 12v fans to a 5v USB pack was a good thing
- Uncomfortable moment on Day 1 when a Chicago screw in my boot came loose - the plate held fine without it, but I had to quickly find a spot to take my boot off as it was like having the most evil stone in my shoe ever
(http://i.imgur.com/3uzEhPh.jpg)
We had a terrific 3 days at Celebration and spent the majority of the time in kit. Indeed, what with the prices on the stalls and the ridiculous queuing times for everything we quickly decided to sack off every aspect of Celebration and spent our time having fun with our Mercs Family - indeed, I think as a first con experience, Jayne and I wouldn't have stuck around for much longer than maybe a day-and-a-half if we hadn't decided to go in costume.
This was our first experience of any type of costuming/cosplay at all and boy, was it fun. I've had a terrific time this past year constructing our gear and had not really been thinking much about what it would mean to wear it - I've heard Adam Savage talk about wearing the costume being the other 50% of the experience - damn straight. On some days it took us a good 30 minutes to get to the booth.
(http://i.imgur.com/s0Ls8ta.jpg)
(photo credit: Niabi)
Highlights of the weekend were:
(Friday) in addition to meeting all members of our wonderful Mando Family, meeting loads of folks who I hadn't seen for years, who happened to be at Celebration and I ended up bumping into by chance.
(http://i.imgur.com/hLIZe5C.jpg)
(This believe it or not is my childhood friend who I went to see Star Wars with back in '78 and our head bridesmaid - we hadn't seen each other in 8 years until Celebration...where we promptly dumped her in a jail cell)
(Saturday) working on the booth for few hours, helping man the jail cell and being a training sergeant for the kids in the games area, attending the Mercs talk and with Jayne, Ryi'nock, Tracyn & others being able to show off our kits to a vast audience of folks who attended
(http://i.imgur.com/jB9v0zr.jpg)
(photo credit: Saz & Niabi)
(http://i.imgur.com/BSxfSNH.jpg)
(photo credit: Saz & Niabi)
(Sunday) helping out with the Family Area and meeting a whole bunch of Dads who, after chatting to them wanted to make their own kits...and I believe some of them have actually started on them here on the boards!
(http://i.imgur.com/ybbzsWE.jpg)
And joining in the group photo and the Honour March with everyone who attended in kit - standing amongst some 50 Mandos shouting 'Oya!' together - that's something, I tell you!
(http://i.imgur.com/diMGqN5.jpg)
(video credit: Slimsidious)
And finally, spending time with Tom (our Mandalore) and the rest of our Mando Family for a terrific meal - never felt more welcomed by so many folks I'd never met in person before.
...and to top it all, a total surprise - Dave Filoni (yes, THAT guy - that guy who could've been at any swanky London meal that night but chose to spend it with us) stopped by the Meal on the Sunday night to say hello to everyone - a really nice chap who had time to talk to everyone...and in fact got into a discussion with Jayne all about her mouse ears and whether or not they could be made canon...
(http://i.imgur.com/8Jp7KS3.jpg)
For more a in-depth report and more photos from Celebration, Jayne's been busy on her blog:
(https://3.bp.blogspot.com/-kqyh6r--N7I/V4_TyQceSnI/AAAAAAAACvY/Pe9HlT4-Py4Y08CXNtcdp5gr9gUwuS7egCKgB/s1600/JayneMiniMando.jpg)
http://jp2mk.blogspot.co.uk/2016/07/wow-what-weekend-day-1.html (http://jp2mk.blogspot.co.uk/2016/07/wow-what-weekend-day-1.html)
http://jp2mk.blogspot.co.uk/2016/08/wow-what-weekend-day-2.html (http://jp2mk.blogspot.co.uk/2016/08/wow-what-weekend-day-2.html)
Oh, and we made it onto the Star Wars Live! stream too:
https://youtu.be/1xfVtfdervc?t=17042 (https://youtu.be/1xfVtfdervc?t=17042)
(http://i.imgur.com/K0XCRI6.jpg)
A truly memorable weekend, an amazing experience and so many lovely people.
When I got back to the hotel on Sunday night I found that Adam Savage's Love Letter to Cosplay talk at TED had appeared in my feed - this dude not only knows how to build costumes, he manages to articulate what they mean too...I recommend sparing some time to watch this...
Oh, yeah...and then, like a week after Celebration, this happened...
(http://i.imgur.com/55hTMaN.jpg)
Um...wow.
Thanks everyone for sharing my journey these past 14 months - I've had such fun, made so many friends and I'm looking forward to helping as many folks as possible in this exciting new role.
Oya!