Boba Fett Costume Build

 For Halloween 2019, my 6yo son wanted to be Boba Fett (with a lot of heavy encouragement from Dad).

This was by far the most involved costume I've ever made.  

Goals:

1. Screen accurate to ROTJ
2. Jet Pack with lighting, smoke and sound VFX (driven by buttons on gauntlets)

The most challenging part of this costume was the helmet.  I needed to make it as small as possible, as my 3'10" 6yo has a head the size of an adult, we wanted to make movie accurate bobafett not bobble head Fett.

To test helmet size, I made test prints using vase mode, so they could be printed in just a few hours (instead of days for the final version).

Once I was happy with the size, I printed the final version in three parts:

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Assembled:

After many hours of painting:

I used a mercury switch so led lights on the targeting rangefinder would turn on when lowered

3d Print of knee armor and gauntlets:

3D print of Jetpack pieces, pre assembly, I made mounts for an amplifier, speaker, and smoke generator

The shoes were a challenge, I found something close to film-accurate and painted and detailed them to match.

I used an adult size display on the armor, so it's not exactly scale

This costume has so many accessories! 

Final Costume!

Of course I couldn't stop there, I also made a Boushh costume for my wife.

The Boushh costume was more of a rush job, but I was really happy with how the helmet turned out.