This Halloween I wanted to make a really cool costume but I had a very tight budget. So I looked around the garage and I found a couple of sheets of cardboard, some blue foam, plastic sheet, some brown vinyl, lots of various colors of spray paint, etc. I also had a flight suit from a previous costume.

The first thought that came into my mind was Boba Fett- the notorious bounty hunter from Star Wars. In costuming circles, Fett is considered to be one of the most difficult, time consuming and expensive costumes there is for a Star Wars character and a lot of people will say that a decent looking Fett costume can't be made inexpensively. I'd like to thank each and every member of The Dented Helmet- the best Boba Fett costume resource for all their help, advice, templates and reference material! Without these guys this never would have happened.

Here's how I made my Fett costume on a limited budget and in a short period of time.

Step 1: Materials

You'll need:
two to three large sheets of cardboard- the sheets I used are called newspaper board (about 1/16" thick and measure 30" x 40") It's available at craft stores and picture framing shops.
hot glue gun with lots of glue
white glue
blue foam board (a section of 2x4 scrap lumber will also work)
sheet plastic- I used 1/8" thick Sintra for the armor (available from plastics suppliers and sign shops) and regular styrene ( for sale signs) for the jetpack missile
some velcro
cotton/canvas dropcloth- available at Home Depot for $10
cotton clothsline- 40ft. or so, about 1/4" diameter
belt buckle (any kind will do but the plastic click lock kind work pretty well)
flight suit- grey is preferred but I had a tan one on hand
lightweight spackling paste
small can of Minwax Polycrylic sealer
aluminum soda cans (four of them)
dark green fabric dye
dark tinted plastic for the helemt visor
spray paint- one can of the following: white, red, olive green, burgundy, black, blue, silver, yellow

There are also several templates that you'll need. This have been graciously provided by Alan (Wizard of Flight) of The Dented Helmet board. All of these templates can be also be scaled down so that a children's costume can be constructed.

Armor templates are here- they are in zip format and they come in three different sizes: http://www.thedentedhelmet.com/forums/showthread.php?t=7825&highlight=armor+templates

Knee templates are here: http://www.thedentedhelmet.com/forums/showthread.php?t=9337&highlight=armor+templates

Jetpack templates are below.
wow. looking at all the detailed steps building the helmet.....it's really quite amazing. Thanks for the instructable.<br>
hey your costume is great fantastic job im in the middle of making my own thanks to WOF and those impressive templates. I would like to know what kind of cardboard you used . and how much spacling is needed for armour pieces
The type of cardboard I used is called newspaper board- it's primarily sold at craft stores and shops that do picture framing. You really don't need much spackling- it's just there to smooth out seams and rough spots.
Just finished the armor parts. Thanks alot for the templates.<br /> <br /> What kind of material did you use for the helmet's visor?<br /> <br /> Keep up the good work I'd be glad to see the boots, gloves and gauntlets coming.<br /> <br /> With best regards from Germany ;)<br />
Glad you like it! I&nbsp;just used some clear visor material (from a safety visor) and tinted it with auto window tint film.<br />
<p>Is the belt strap for the ammo belt made of just vinyl or is there a base you covered with it?</p>
I finished my mandalorian armor cosplay just in time for Emerald City Comic Con 2016! I had so much fun making it. This instructable was very helpful ?
<p>this is my costume... I copied the paintjob,and other stuff from someone, but don't be fooled, its cardboard.</p>
<p>Where did you get the flight suit?</p>
Wow- that looks great!<br>
I was wondering if you could possibly make a bobba fett costume for me. I'm going to wondercon in March and this will be my first wondercon/comiccon event and I don't have much time to make a costume because of school. Any way you could make me a costume and I'll pay for the expenses and time?
Sorry but I can't make costumes for other people- not enough time!
<p>this is my costume... I copied the paintjob,and other stuff from someone, but don't be fooled, its cardboard.</p>
<p>Thank you, I wanted to dress up for the opening night of star wars, but didn't have a costume...</p>
<p>How do we make his gun???????????</p>
I would probably do a search for templates or at least a side view line drawing and then make it using MDF and PVC pipe.
With the 1/8&quot; sintra sheets, did you use the Sintra with the foam in between the 2 sheets or the solid pvc sheets?
I used solid sheets.
Also, how did you cut the plastic? Could you use a regular cardboard knife?
<p>I used a scroll saw but a utility knife should work.</p>
Do you remember what the plastic was called when you bought it? A specific name might cone in helpful.
<p>The plastics shop where I purchased it just called it Sintra- I've never heard it called any other name. There's more info about it here-</p><p>https://www.lairdplastics.com/product/brands/sintra</p>
<p>Where can you find the Sintra, snaps, Minwax Polycrylic sealer, and epoxy? I plan on making Custom Mandalorian Armor for PAX Prime this august.</p>
Sintra you can find at plastics/sign making shops. The other materials you can find at many hardware stores.
Thank you :)
<p>hi there, can you say me, what is the material you made this jetpack of? I mean, what is the sort of cardboard it is and where i can find it? p.s sorry for mistakes, that's not my language at all:)</p>
<p>From the materials list- </p><p>&quot;two to three large sheets of cardboard- the sheets I used are called <br>newspaper board (about 1/16&quot; thick and measure 30&quot; x 40&quot;) It's available <br> at craft stores and picture framing shops.&quot;</p>
i all done step 4/
would pop bottles be ok to build the jet rocket? I'm stummped
I'd say use whatever you can find!
How wide is the back pack and how high without the missile on top? How tall is the missile? Reason for asking is I am 6 foot 1/2 inches tall and my shoulders are 58 inches across.
I don't know the overall dimensions- I gave my costume to a friend several years ago so I have no way of measuring it. I do know that the patterns are dimensioned from the movie jetpack and the actor that played Fett is 6 feet tall so you should be just fine.
hey guys, if worst comes to worst, you could always just grab some 14 gauge aluminum sheeting, cut it out, and dish it a bit to fit your frame.
Quick question, is the backplate attached to the flack vest? if so how did you do it?
It's attached to the flak vest using snaps.
Whats up! Im almost done my Boba Fett costume for Halloween! I honestly couldn't have done it without your tutorial Honus. I just need to do the Boots, Gloves, Blaster, and attach the Cod Piece and back belt to the suit. I finished the jet pack today, and it turned out amazing. I'd just like to thank you for taking your time to put up this tutorial, It really helped me out alot!<br><br>I'll post pictures soon!
That's great! I'm so happy that the instructable helped- can't wait for the pics of the finished costume. :)
I'm pretty much finished with my jet pack. I'm twelve and i'm making the empire strikes back version which is green. I did this just by the pics of yours.<br> I haven't done the thrusters yet.
That's great! Make sure to post photos when you're finished!
I just made my armor out of cardboard which isn't the best but couldn't get the <br>sintra sheet but it still looks pretty good.
I'm going to try and make this out of 0.8mm steel in the holidays, I'll post pics when I'm done. <br>PS I'm on thedentedhelmet as well
Wow- that will be quite the project! I once made a proton pack wand from steel and I think it took me around 30 hours...
I estimate the jetpack will take about 2 0r 3 days, The helm the same due to the bends, 1 day each for the gauntlets, 1 day for the platebody and knees.<br><br>That's only if the steel supplier replies to my product inquiry!
hey, what about the gun?
I never got around to making it.
Is there a template for the gun? Thanks.
I don't know of one.
oh, ok then
did you finish the gauntlets and every thing al ready or not i would like to see how you can make cardboard gauntlets :P

About This Instructable




Bio: I'm a former bicycle industry designer turned professional jeweler. I like working with my hands and am happiest when I'm in the shop ... More »
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