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How to scratchbuild a Boba Fett costume- using cardboard!

How to scratchbuild a Boba Fett costume- using cardboard!
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  • Fettcostume2.jpg
  • jetpackfinished1.jpg
  • vestfinished.jpg
  • helmetfinished.jpg
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.
 
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Step 1Materials

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.
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258 comments
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Apr 8, 2010. 12:29 PMNihkoute says:
Just finished the armor parts. Thanks alot for the templates.

What kind of material did you use for the helmet's visor?

Keep up the good work I'd be glad to see the boots, gloves and gauntlets coming.

With best regards from Germany ;)
Sep 25, 2010. 11:37 AMlysa613 says:
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
Oct 10, 2010. 9:24 PMmcorbin says:
wow. looking at all the detailed steps building the helmet.....it's really quite amazing. Thanks for the instructable.
Mar 29, 2012. 1:59 PMGabriel Van Helsing says:
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.
Nov 1, 2011. 9:08 PMlucydavi says:
Quick question, is the backplate attached to the flack vest? if so how did you do it?
Sep 30, 2011. 8:14 PMlucydavi says:
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!

I'll post pictures soon!
May 16, 2011. 4:03 PMMandolorianFan says:
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.
I haven't done the thrusters yet.
May 16, 2011. 4:07 PMMandolorianFan says:
I just made my armor out of cardboard which isn't the best but couldn't get the
sintra sheet but it still looks pretty good.
Nov 15, 2010. 12:07 AMminerug says:
I'm going to try and make this out of 0.8mm steel in the holidays, I'll post pics when I'm done.
PS I'm on thedentedhelmet as well
Nov 16, 2010. 3:33 AMminerug says:
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.

That's only if the steel supplier replies to my product inquiry!
Feb 15, 2009. 2:23 AMThe Jamalam says:
hey, what about the gun?
Nov 1, 2010. 9:30 PMminerug says:
Is there a template for the gun? Thanks.
Feb 15, 2009. 9:15 AMThe Jamalam says:
oh, ok then
Oct 29, 2010. 8:46 AMroragul says:
did you finish the gauntlets and every thing al ready or not i would like to see how you can make cardboard gauntlets :P
Oct 9, 2010. 8:28 PMMusicman41 says:
Is it just me, or does the jump pack seem too brightly colored to match the rest of the costume?
Oct 12, 2010. 12:14 PMfight4gipper1 says:
Ya, It looks a little too much like Buzz Lightyear
Jul 23, 2010. 11:27 AMSirNoodlehe says:
Its extremely cool and I'm making it I just noticed that you don't have kneepads, ankle pads or wrist armour but it still looks great
Aug 30, 2010. 9:47 AMsnowaure says:
Hello, whats is the PDF print % to the jetpack? 100% or 730%?.let me know thanks........
Nov 2, 2009. 7:56 PMbobafettman says:
finished! just in time for halloween! thank yiu so much you were a great help.
along with everyone at thedentedhelmet especially wizardoflight!
Apr 2, 2010. 2:02 AMBobaFettFan says:
 i put the spackling paste on and its just chipping off any tips
Nov 1, 2009. 12:29 PMl96470fps says:
wow !! you are amazing especially with the cardboard and painting, are you an artist or just a genious craftsman?!
Oct 31, 2009. 11:16 AMdepotdevoid says:
Oh very nice, I'm quite impressed!  The helmet detail in particular is amazing, especially considering that you used cardboard.
Oct 29, 2009. 8:09 AMgar-gar says:
it stinks when your cardboard gets wet from rain right after you spray paint
Oct 28, 2009. 3:09 PMgar-gar says:
it is 2 days before halloween how do i get it to print the right scale
1-40 of 258next »

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Author:Honus(Multi-Bot)
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 building my creations. If you need help with your project just let...
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