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[Zorim Dran]

So. I've done a couple of costumes before, but nothing Star Wars, and nothing I actually had to build, so this is new ground for me. I'm also trying to do this on a budget, using ideas from various threads I've found around the forums.

I've seen a number of threads on cheap builds for various items, but none of them seem to have actually finished. I'm hoping I can use what others have started and make a complete accounting of my build and its costs.

Here's my MandoMaker concept:


Here's a list of items that will make up the costume, and their cost (Trying to account for everything that I need, list will grow as needed):

UPDATED 9/4/12: Kit approved, Final tally.

Soft Parts

• Flightsuit ($25)
• Black Dye ($2)
• Pouches ($10)
• Gloves ($15)
• Vest, Duck cloth and thread ($15)
• Belt ($4)
• Boots ($35)

Armor Plates

• Plastic Totes, 2 ($10)
• Velcro, Sticky Back and Sew-on ($15)
• Elastic Strapping ($3)
• Snaps ($2)

Helmet

• Hasbro Boba Fett Helmet ($11)
• For Sale sign ($3)
• Welding Visor ($10)

Gauntlets

• Toilet brushes, 2 ($12)
• Continuous hinge ($8)
• Platform Bases ($2)

Weapons

• Hasbro Boba Fett Blaster ($20)

Tools/Hardware

• Hacksaw ($7)
• Hacksaw blades, 5 ($3)
• Hand sander with sandpaper ($12)
• Spring clamps, 2 ($2)
• Heavy Snips ($8)
• Nitrile Gloves ($2)
• 2-Part Epoxy ($5)
• Plumbing Epoxy ($5)
• Spraypaint ($36)
• Bondo ($9)
• Fiberglass Resin ($13)
• Glazing Putty ($4)

Final Cost at approval: $263

First piece I obtained was I flightsuit:

I picked it up at a local Army Navy Surplus for $25. 100% Cotton. Had to remove German flags from the sleeves, but otherwise seems great.

Next piece was a trenchcoat.

$8 on a 50% off clothes Wednesday at the Salvation Army. I'll be cutting it up to make a vest (per Ohld Vart's guide http://mandalorianmercs.org/forum/index.php?topic=21956.92), and if I can, a kama as well.

The armor plates will be made from totes, (per Mar'eyce's guide http://mandalorianmercs.org/forum/index.php?topic=21956.0) I've heard conflicting opinions on its workability, but I can't ignore the cheapness factor here.

Gauntlets will be from toilet brush holders (per Condar Ward's guide http://mandalorianmercs.org/forum/index.php?topic=43869.0).

I'm planning on buying the Rubies 2-piece Jango for the helm. Scratchbuilding is a little too intimidating for me on my first go around. I'm not very big, the size should be alright.

That's all so far. Hope to start on plates soon. If you see anything missing from my list of needed items, let me know, and any other tips, comments, or advice are perfectly welcome.

[Remo Jadd]

As you said, your list will probably grow. My main advice for you, is take your time, don't rush and good luck .

[Calo Ordoa]

Excitement! *Settles down with a bucket of popcorn and a large Dr. Pepper*

[Niabi]

take your time, don't rush and good luck .

^^ This^^

I like you concept vod i shall be following you build

[Jesse Libarra]

looks good so far. As I am starting on my very first kit myself, I shall be watching your progress with much interest. 

[Teilyr Farsel]

As you said, your list will probably grow. My main advice for you, is take your time, don't rush and good luck .

Your list with AT LEAST triple in size.  Then, after you think you're done, BAM another idea pops in your head and you're going again.

Good luck with your build, and as said.  Take your time, do it right the first time, and enjoy the steps it takes to make a great kit.

[Zorim Dran]

Alright, trying on some templates for sizing. These are the Jango WOF Medium chest and belly plates, but they printed slightly smaller than they should have (the 5-inch line was ~4.8 inches). I'm not sure about the sizing here:



Should I go up to large plates? Or just get the Mediums to their correct size? Or good as is?

[Remo Jadd]

Sizing looks about right .

[Zorim Dran]

Got my materials for the plates today, list updated with new items/prices.

Taped on my templates, and traced them out with a sharpie:





That's not all of it, but you get the idea.

Managed to get the chest and collar cut out.



Even with the heavy snips the cutting is hard work. I'll get to the rest tomorrow.

I don't have large enough totes to just cut a back plate, so I'll need to work out something segmented.

[Jesse Libarra]

It looks good so far.

[Karvas Dral]

Rotary tool, ner vod!
It'll save you so much trouble!

[Zorim Dran]

Rotary tool, ner vod!
It'll save you so much trouble!

While it would save a lot of trouble, it would spend a lot of money, which I'm trying to avoid.

Woke up the morning after my last post to my right hand killing me from all the snipping. My palm and fingers where I was pressing against the snips to get through the totes were sore as hell. So I've slowed down quite a bit on getting things cut out. Dremel sounds pretty sweet right now, but I press on.

I have made some progress:



I couldn't find a template for knees in a flat or dartless style, so I took the center kneecap from another template and added the side hooks in Illustrator. I think they look good, but we'll see how they turn out in the end.

As the back plate goes, I found that the lid to the tote is just about big enough:



But it has this dip near the edge:



Anyone know how easy it would be to shape that curve out, or make a different shape of backplate to accommodate it?

[Karvas Dral]

I got mine for $30 is that out of your budget?

[Zorim Dran]

It's less a matter of whether I have the money than must that money be spent. I want to spend as little money as necessary to get the kit together, to see what it comes out to total. So anywhere I can cut a cost without sacrificing quality (i.e. it costs less, but takes more work), that's what I'm gonna do.

Mar'eyce's guide said it could be done for ~$150, and I want to see how close to that I can get while still making the kit that I want. Awesome as that guide is, and as much as it has helped me so far, it never finished, so we never got to see a final total on it.

[Razeontil]

Me and the wife are making our first kits as well. I shall follow your progress with great enthusiasm. Also we got a rotary tool from a store called harbor freight tools for $10.00 it's cheap but gets the job done.