Burt's Build I wanted to go through and document my build. I started this in January 2020.
First thing I did was order soft parts from Gwabo Butt on Facebook. I've had issues with custom sizing in the past, so just for my own sake, I ordered a regular 'medium' knowing full well I'd take it to my local tailor to get it sized properly to me.
The first helmet I printed was Rob Pauza's file on myminifactory.
Printed in one piece on a CR-10S, sliced with Simplify3D, with 3Dsolutech 1.75mm PLA. Paint color is Rustoleum Bright Chrome and “sanded” to darken it with a paper towel. Visor is a Hobart replacement welders visor.
This is a really good light weight helmet.
My second Helmet is an L.E Props cast
The quality is magnificent.
I bought this cast since it was one of the best I'd seen, with the full intention to use Screen Accurate paint, Alumaluster.
I've never airbrushed before, so I bought a kit on amazon ($100) + the Alumaluster ($100). Did I mention I've never airbrushed before?
I bought this back in ~March and put it on hold. I feared the summer humidity would not let me paint this.
I planned to get this build finished before Megacon, but things
really flipped upside down, so I spent less time on this costume over the summer. I would slowly putter around on it a few nights a week, really working through the details of this costume.
While I waited through summer, I worked on more parts.
I've never done leatherworking before, and with my rookie sewing skills, I could probably make a leather bandolier on my own. I was just dreading the pattern making, especially with how this entire belt is positioned on your body. I used the D23 reference images for most of the measuring.
It turned out really well for my first go. I 3D printed the bullets, since I didnt want too much weight on this belt, but I did order the metal gun attachment + metal belt buckle from JJ industires. They were just too good to pass up, and I really wanted a real functioning gun attachment.
I 3D printed all of the parts similar to that of the helmet above. All on my CR10S. I mostly used Great Ape Studios (Chest, Back, thighs, shoulders), and Plastic Arms Studios (gauntlets, knee) and Sean Fields (shin) and some free files (grenades, bandolier parts, pistol)
I ordered the Amban Rifle from Traywick Studios (not yet pictured because it's really big)
For the gauntlets, I used a really simple attachment system. Magnets, hot glue and nylon webbing.
For the Left Leg, this was something I was
dreading . I saw a few different ways to do this, but I wanted something I could slip my foot into and out of without thinking much about it.
I took a sheet of Sintra and cut it to my shin size, heated it and wrapped my leg with an inch space in the back for flex. I then measured out the different parts and started at the bottom.
5 rows of leather for the bottom part, sewed together (not sure what you'd call it), then glued the end to roughly where I thought to put it, with a row hanging off for flexibility.
Next was the orange band with the 'tombstone'. Tombstone was 3D printed then wrapped. There's a piece of velcro on the back of the tombstone holding it in place on the sintra, and then velcro on the back to attach.
The big wrinkled part was hard to get the correct screen accurate affect. I took strips of EVA foam and cut them/dremeled them to give them shape and just glued it to the sintra. I then just glued the leather to that, which makes it look permanently wrinkled.
The top band was the easiest, I just used the D23 reference images. Used 2 colors of leather, and stained the middle band. Made a pouch with the same pattern as the bandolier, but with a strap and extra stud.
(measurements from the Din Djarin Mandalorian FB group)
For the knee, I made sure I had the correct details with, and attached with a large piece of webbing and velcro. Basically there's 2" wide webbing, with hooks side velcro, and then a section on the knee with soft velcro, and a section on the sintra below, the long strip holds them both in place. The webbing is thick enough and rigid enough to keep it upright.
I custom made my grenade plate for the belt. I wanted real metal, but also something light weight.
Magnets help attach the grenades to the aluminum plate. I plan to add a chicago screw to better affix this to the belt, the clip is great, I just want something a bit more permanent.
For attachment to most parts and pieces, I used velcro and 2" nylon webbing.
For the Shoulders, I used EVA and foam padding to 'buff' them out. I used larged 1" snaps to attach.
Weathered gloves and hand plate. Just dip your fingers in some watered down paint.
Gio's Boots. Sanded with sand paper.
Test fit before weathering.
For the Alumaluster Helmet, I used plain Rustoleum Gloss black for the undercoat.
Then used the Alumaluster with an airbrush, no thinner. Shake the bottle and pour in and paint.
My most recent test fit after everything is finished. I'll take submission photos once I change a few more tid bits.
