Lego Boba Fett Costume

My son is a huge Lego fan, therefore, I'm a huge Lego fan. I've always been a great fan of Star Wars, therefore, my son is a fan of Star Wars. With that said, he wanted me to make him a Lego Boba Fett costume. This is his third Lego Minifigure costume that I've made for him but none of them were as involved as this costume.

I built the costume from scratch and spent in excess of 100 hours over a period of a few months. I worked evenings and weekends, whenever possible. Material costs were approximately $300 as I used custom paint on the helmet and jetpack.

The costume was constructed primarily out of a 1/8" thick PVC foamboard called sintra and cost $40.00 for a 4' x 8' sheet. Pink insulation foam was used to carve the helmet dome and some closed cell plastazote foam was used on the jetpack rockets and Lego head base. Plexiglass was used for the "T" visor in the helmet and was also the vision.

I treated the costume much like the actual minifigure and made some of the elements removable. The Antenna is pressure fitted and can pop on and off. The jetpack is removable and fits into slots I created on the torso.

The graphics used on the torso and legs were created by scanning the actual minifigure and redrawing each design element in Adobe Illustrator. I had the graphics printed on vinyl adhesive for approximately $30.00.

The costume uses such techniques as foam carving, heating and forming the PVC foamboard, as well as standard cutting and gluing. There was a lot of finishing techniques on this costume including; filling seams and flaws with Bondo glazing putty, sanding and priming,
The costume used a few types of spray paint and a custom spray paint that is latex house paint compressed into a spray can.