Let's face it, $350 is a lot of cash to be throwing down to purchase a molded jetpack kit to complete your Boba Fett costume. Fortunately, it's not impossible to put together a jetpack from scratch (at least that's what I told myself when I started this project). It's taken me five weeks, and I wanted to share my process in case it might be helpful for others.
My main materials were:
They gave me both for free. :)
I also used:
As far as tools go, I used quite a few different tools, but the main tools were:
Ok. Let's get building!
I used the 1/4" sintra to start things off and build a solid structure for the rest of the pieces to attach to. Get ready for a ton of cutting. If you use a exacto for the whole thing, your fingers are probably going to fall off, so I highly recommend a box cutter for most of the cutting. You can also use metal shears to rough cut the pieces before trimming them more closely, if you happen to have a set on hand.
The great thing about sintra is that since it's PVC, it bonds with PVC glue. To strengthen the connection, I tried gluing a small piece of pvc tube in the corner, but this wasn't the way to go. Instead, I used a heat gut to heat some small rectangles of pvc and bend them into 90 degree angles. Slapped some glue on that, and it was perfect for a bracket.
I built the bottom of the jetpack and used four small spacers to shim the bottom grill away from the other piece.
To curve the back, I used a heat gun in the area where the fold needed to be, then I set a board on top and used that to keep the bend straight. Repeated this for the second bend as well.
To give some thickness to the top of the jetpack, I glued another piece to the top and shimmed it out with small pieces placed lower on the jetpack. I let this top piece overlap the top edge, and once it was dry, I used the box cutter to cut the new piece flush with the other. Then, I rounded it off with a sander.
The cardboard tubing was attached using Gorilla Glue.
Now, let's build those fuel tanks...