Topic: Making Mandalorian Armour
A few people have expressed an interest and asked for advice in making Mandalorian armour, so with that in mind here's a simple guide to Mandalorian costume making.
3mm/5mm foamed PVC sheets (Sintra, Foamex etc.).
Printed armour Templates.
Flightsuit or two boiler suits
Trophies (Wookie braids etc)
Templates - In order to get the shape correct you'll need to download some printable templates.
Jango Fett's templates can be found here: http://www.kotemandos.com/forum/index.p … ;#entry485
Boba Fett's templates can be found here:
Alternatively templates for either can be found at www.thedentedhelmet.com
Print the templates out and cut them out before using them to mark out the required shapes onto your sintra. I recommend 5mm sintra as it gives a deeper, more realistic look but 3mm will do the job (or even aluminium of you feel like working in metal.)
I suggest using a jigsaw as it can be hard work and time consuming otherwise. Once you have the basic armour plates cut out and sanded smooth, you'll need to give them a slight curve. There are several ways to do this using sintra. The first is to use a heatgun (available at any DIY store) - don't use a hairdryer as at best it'll over-heat and break, at worst blow up! The second way to bend sintra is to use a large bowl of boiling water and immerse the plastic into it. What ever technique you use do not place the sintra in the oven as it will give off toxic fumes.
Use a picture of Boba or Jango as a guide to how much of a curve you need to add to the various pieces.
Once you've got armour cut to the right shape and size for you and given the right curve you are ready to paint.
Flightsuit - There are plenty of accurate Boba and Jango flightsuits available to purchase out there and some suppliers that will even make a flightsuit in a different colour if asked, but if you fancy giving it a go yourself you'll need 2 identical boilersuits/ overalls in heavy cotton.
First remove the sleeves of one of the suits and put the now armless flightsuit to one side (to be used as spare matching material). On the second suit chop the arms to T-shirt length and attach the arms from the first INSIDE the t-shirt sleeves on the second - This gives you the important outer short sleeve.
IF you are doing Boba's flightsuit (or your Mando wears a similar style of flightsuit) use material from the first suit to make thigh pouches. IF you are making Jango OR your Mando wears full armour then you'll need to cut slits in the thighs and shins for the straps of your armour to go.
Vest - There are several patterns and styles to choose from depending upon if you are making a Jango or Boba style vest. Additionally you can purchase Boba and Jango vests from reputable dealers. WHAT EVER YOU DO, DO NOT CONVERT A JACKET OR BODY WARMER AS IT DOES NOT WORK. Once your vest is complete you can then sew either industial strength velcro or attach heavy duty poppers to the vest (using your completed armour as a placement guide) - Get a friend to give you a hand at this stage as you'll need help to mount it correctly.
Helmet - You CAN purchase Rubies Boba and Jango helmets - but in my honoured opinion they're not worth the time and effort you'd need to put in before you get something that everyone else doesn't laugh at. Reputable and reliable dealers can be found on The Dented Helmet and www.501st.co.uk and the helmets are accurate movie sized helmets made from fibreglass. BE CAREFUL IN REGARDS TO PURCHASING FROM EBAY.
I'll keep adding to this (as you can imagine it's a little time consuming to write!) in the mean time I recommend www.kotemandos.com and www.thedentedhelmet.com for invaluable assistance and more indepth advice on making a Mandalorian/Fett costume.