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[Luthien]

For my "pandemic project", I've begun the process of building Bo Katan from Clone Wars Season 7, and am slowly becoming aware of the various differences between this version and the other versions.  Before I was aware of some of these differences, I purchased an armor kit from Imperial Surplus.   I hope that I'll be able to modify some of the pieces, or acquire replacements for those I can't change.  In addition, I've already communicated with Delta13 for the belt, pouches, etc that are unique to this build.   

I'll be posting pictures of my progress along the way and hope you all can guide me through this!
Chris

Supply list:
Armor:   Imperial Surplus
Belts and straps:  http://deltaleatherworks.com
.stl file for strap clips: https://www.dropbox.com/s/n8r2ga062paq00q/bo%20strap%20clip.stl?dl=0
Gauntlets: https://www.etsy.com/ca/listing/467195204/bo-katan-night-owl-mandalorian-gauntlet?variation1=628660315&variation0=567023503
Jet pack: https://www.thingiverse.com/thing:4184843
Flight suit:  https://www.amazon.com/Hanes-Womens-Stretch-Jersey-Legging/dp/B01I21GX40/ref=sr_1_9?dchild=1&keywords=womens+jersey+stretch+pants&qid=1625610218&sr=8-9

https://www.amazon.com/gp/product/B07SL6BFP2/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

LEDs for gauntlets:  https://www.amazon.com/gp/aw/d/B07P6L6FSF?psc=1&ref=ppx_pop_mob_b_asin_title

[Luthien]

I started with the bucket.  I've got it trimmed up and ready to paint....
44FEA5DB-9E94-4668-83AF-5771AE38DCFF by Beren97, on Flickr

1E6FFD55-2D34-4D37-9F23-8A8394A41CDF by Beren97, on Flickr

35669F47-2499-4C09-A597-CAE63B508176 by Beren97, on Flickr

[Kryamla Redalur]

Commenting to follow along

[Luthien]

More work done on the bucket prior to painting.  I used a cardboard template to determine shape of the lens material, and then placed a pair of countersunk screws on either side to secure the lens.  These will be covered over next with Bondo and sanded...
18DF5FF8-F0F6-47A4-8A82-E78675ED145C by Beren97, on Flickr

54D521A4-E5E7-4EB4-9BA1-AE444FC1CD8B by Beren97, on Flickr

A4585160-F8EB-4DC8-9763-D82482301C48 by Beren97, on Flickr

F78B5A93-56BC-4C32-97D8-F9257F87CCF9 by Beren97, on Flickr

C029FD4D-CA5F-42E5-BFA0-9B04D9156B65 by Beren97, on Flickr

A03DFDD8-1BD2-41F9-A2DF-70C07241F3FF by Beren97, on Flickr

680F36D2-00AA-4641-9762-2B370A447EF0 by Beren97, on Flickr

[Luthien]

With the helmet done, I've decided to next work on the thigh armor.   Of all the pieces, why the thighs???  It's certainly not because they are the most exciting pieces to trim, but I am hoping to place my order for belts and straps, and the thighs need that piece of leather behind them. 

The challenge is that the thighs in the Imperial Surplus kit don't match this particular version of Bo Katan, so I've done some trimming.  My goal is to reproduce the shape on the back of the leg as seen here:
BB043C20-5211-4A77-93C1-F4D0F52AE993 by Beren97, on Flickr

Imperial surplus armor before modification:
6C6AC270-2FC9-42E9-89E5-D519CABB47CA by Beren97, on Flickr

Modifications:
DF917E1A-4AC1-4098-8C7E-521E5F394FE8 by Beren97, on Flickr

5C085169-56AA-48D1-9669-D8DFA1772A84 by Beren97, on Flickr

I tried to create a return edge with a hot iron, but the plastic was too brittle afterwards and broke away.
D8151484-6D79-4618-972A-E8D903AED8FE by Beren97, on Flickr

After sanding:
59B24C54-FEEA-4BC2-9406-E33B1D772E2E by Beren97, on Flickr

Cardboard template used to create identical shape for opposite thigh:
38BACF88-F886-48D4-BFF2-6128A8A99340 by Beren97, on Flickr

475B8D80-EC5C-4D9D-95FD-8CF3FBEF32BA by Beren97, on Flickr


So given that the shape better matches, how much if any return edge is recommended?  With the leather piece backing the armor, it's hard to tell if any return at all is necessary.

[Luthien]

More work on the thighs...  I used a heat gun to correct the shape to match my leg size and made a cardboard template to assist with sizing of the thigh plate leather...
7FB5E8E2-B306-464E-A36C-CA41D6A92F9C by Beren97, on Flickr

9006A83F-2CE8-4A9D-AA23-32B297CFE1C7 by Beren97, on Flickr

[Ruus bal'Neta]

I have used a thin strip of 3mm sintra to create a return edge. Its easier to cut and shape than trying to heat and bend ABS.

[Luthien]

I've got the thigh armor finished for now...  holsters have been attached.  I'll clean up the small gaps later with Bondo.  I ordered my leather parts and will work next on flight suit and chest armor.
11F2FFFD-6C56-4389-B1CF-6F51ACCC3DF5 by Beren97, on Flickr

4210FD9F-EC86-4B8A-B241-A0A44B0F6831 by Beren97, on Flickr

BDF9DC33-AF4C-45F9-9055-CA7718F3BFC5 by Beren97, on Flickr

3C7A88B8-676E-42BB-9C9A-68612D1EA8C0 by Beren97, on Flickr

[Kryamla Redalur]

Looking good!

[Luthien]

Looking good!

Thanks Emily!

[Luthien]

I have been searching for a suitable flight suit option, and now have a collection of various "charcoal" colored tops and leggings at home from Amazon!  I really like the leggings made by Spaulding, but they don't make a matching top.  The closest match is pictured below... will this be adequate considering the belts will cover the transition?
3C7A3DE3-8616-4DC0-9717-0B99C0403BD5 by Beren97, on Flickr

F0F3A93D-0478-408B-8DC1-61A3843555F9 by Beren97, on Flickr

[Kryamla Redalur]

I’m not on the approval team but I’m not sure they’re quite close enough unfortunately. Perhaps you can try dying the top to be a slightly darker shade of grey?

[Sabine]

Have you tried searching "thermal sets"? that's usually what gets me matching tops and bottoms.

[Luthien]

Thanks for the flight suit feedback... I'm not completely thrilled to have mismatched stuff, and am not confident in my ability to dye one to match the other.  I've ordered some options in black and will see how that looks next.   The challenge for me with thermals and Underarmor is finding options with the turtle neck. 

[Luthien]

While I await the arrival of my next flight suit trial, I've got the helmet and shoulders bells painted up.  For the helmet range finder, I tried to modify the stem in the Imperial Surplus kit to better match what is seen "on screen".

Screen shot:
263EF695-70D6-442E-AB35-89E46E890C58 by Beren97, on Flickr

7DA4DE58-0327-4056-9A7B-860F9B0147FF by Beren97, on Flickr

884DD794-5840-42F3-9A3D-839FDF56ADB3 by Beren97, on Flickr

6DABEF57-6DB9-4F6B-971C-7FA14A35E0C0 by Beren97, on Flickr

A588FC44-F0BA-4430-8EA0-37D8F905ACBB by Beren97, on Flickr

B37CC372-5709-4A87-AB00-F53E6AEF6C06 by Beren97, on Flickr

Disclaimer... I have no such talent for painting, so I've connected to a local builder who I consider an absolute artist!