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[Billythebrick]

Well we've already gotten a lot of work in on this before we remembered to start our thread, but at least it isn't finished already 

Might as well start with our favorite part so far - our helmet!


Our soft parts are all finished except for final weathering (which we're waiting until the whole kit is done before doing that).

Shirt and vest.

Pants.

We opted to make the flightsuit in two pieces to make bathroom breaks easier


Our gloves and hand plates are also done and ready to go! Hand plates and the rest of our armor all came from Danny Redman as raw casts.


And lastly, for now, we decided to try our hand at metal casting for the first time. We modeled, printed, and molded these holster belt clips and then cast them in metal since they are going to be some heavy lifting.

[Falke]

It's great to see another Bo Katan in the working. I will follow your build!

[Billythebrick]

Managed to get a few more pics uploaded so this thread is almost up to date with where we actually are with the build


Here are all of the armor pieces we're using. All of them except the over the shoulder straps are from Danny Redman. The straps we made ourselves. This is after the first pass of primer and sanding but all of the armor parts now, sans gauntlets, are much further along (more pics coming soon). The knees are done and the rest have all been prepared to a state of raw Beskar and ready for painting and weathering


Our belt is also completely done! We modeled, molded, and cast our own belt buckle since it isn't functional or load bearing, a resin cast was fine!


And while we don't have a pic yet of them all assembled with the belt (we will once the hip plates are done and our connection point between them and the holster is finalized), the holsters are complete! We formed Kydex over the resin Westar 35s (also from Danny Redman), and then covered them in the same vinyl we used for the belt.

[Rilal Birom]

While this entire build is looking AMAZING, I am most impressed with the cast metal parts!  Nice job!

[Billythebrick]

While this entire build is looking AMAZING, I am most impressed with the cast metal parts!  Nice job!

Thank you so much! We like to try to do at least one new technique on a new build and metal casting is something we've wanted to try for awhile and this seemed like a great intro project for it!

[Billythebrick]

It's been awhile but that's because we've been crunching away not only on this build but some other stuff for a con last weekend where we got to do our first test drive! This post has a handful of the WIP photos from the past month. The next one will have some from con once we got it on at the con!

All of our armor parts get the same base treatment - black base, Spaztix Mirror Chrome, then a 2K clear coat. Then the technique varies between the blue and non-blue parts. For the non-blue armored parts, we custom mixed metallic black and metallic gunmetal airbrush paint to get a paint that was a couple of shades darker than our clear coated chrome. That was sprayed over the entire piece and then the edges hit with a lightly damp paper towel after about 5 minutes of drying to get the edge wear and scrapes.





For the blue armor pieces, the next step is using masking fluid for the wear and paint chipping to ensure real visual depth of wear versus just painting them on top of the base paint.



For the pauldrons, just like on our helmet, we did multiple layers of masking fluid along with stencils to get a proper chipping and layering of paint colors.



It can be tricky to match weathering with older parts which is why we usually try to do them all at once, but we managed to match up the pauldrons to the knees we finished ages ago, pretty well!



The one piece we hadn't even started on yet as the con quickly approached was the jetpack, so we did what any crazy person would do - resin printed the whole thing so we could get it ready for paint in just a bit over a day! It got a treatment similar to a combination of both of the above since it has both the blue and non-blue look on various areas.





And that pretty much wraps up our WIP in short.

[Billythebrick]

And here are some pics of the finished build from the con. As with any first wear, we found a handful of tweaks we need to make, but overall, we were VERY happy with how it all come together, especially considering the very last minute rush at the end!


Here's one we took with our darksaber out in front of our booth


One we edited into a still from the show


One taken at the Triple Click Photo Booth


And lastly, one with Dadalorian - Don't Feed Him After Midnight!

[Billythebrick]

And finally got to take our app photos after dealing with kids and Halloween!

[Mi'ix]

Really solid build.  Couple things I'm seeing.

The blue seems really bright to me.  This is coming off as more of an electric blue.  Under the con lights the color looks better, but in these picture it's really bright.

Noticing some floating on your back plate, specifically the upper right side.

The helmet is missing a fair amount of paint damage on the right side.



Any plans to add the yellow triangles to the jetpack?





They are faint, but are there.  Top of the beacon should be a brass color as well. 

Can we get some better shots on how the shoulder straps of the armor go into the back plate?  I'm seeing a straight line when there should be a double layered slot.





Really lovely build, but still a few details to sort out.