Introduction: Star Wars Han Solo Boots

Picture of Star Wars Han Solo Boots

Make a pair of Han Solo Boots! Don't let them fool you, they were made with a lot of simple tricks and nonsense...



Step 1: Creating the Pattern

Picture of Creating the Pattern
Supplies Needed:

Tools:
  • Pins
  • Scissors
  • Pencil
  • Ruler
  • Tracing Wheel
  • Boot (to copy)

Materials:
  • Muslin Fabric
  • Paper

I came across this post here and was inspired to create a pair of boots! For this project I decided to copy a pair of existing boots that have seen a lot of wear and geek them up with some Han Solo details.

I began the pattern making process by pinning pieces of muslin fabric onto each section of the boot and marked the seam lines with a pencil.

Once all the seams were marked, I unpinned the muslin from the boot and transferred all of my markings onto pattern paper using a tracing wheel. After creating the basic pattern pieces on paper I measured all of the seams and corrected any areas that did not match correctly. Once all of the seams were corrected I added 1/4" seam allowance to the edges and cut out the final pattern pieces. 

Whenever I make a new pattern I always do a test run out of cheap fabric to make sure I like how everything fits. Using my pattern pieces I sewed a mock up of one boot out of felt. Luckily everything fit perfectly and I had my pattern complete which I used for both the boot and the lining.

To complete the design I arranged the details of the Han Solo vest and belts on my mock up boot and once I had everything in place I was ready to get started on the real thing!


Step 2: Sewing the Boot Lining

Picture of Sewing the Boot Lining
Supplies Needed:

Tools:
  • Boot Pattern
  • Sewing Machine
  • Scissors
  • Pins
  • Pen (I used a metallic pen to show up on the black fabric)

Materials:
  • Black Faux Fur
  • Black Thread

Using my boot pattern I marked and cut each piece out of faux fur for the lining. Since the fabric I had was fairly thin I doubled the fabric on each piece and used a zig zag stitch to finish the edges. 

Once the pieces were all cut and ready to go, I started sewing them together. I used a 1/4" zig zag stitch for everything and I started the process by sewing the front and toe pieces together. Next I attached the front and back pieces together at the side seams. Then I finished by sewing on the soles. 

Step 3: Cutting the Boot Pieces

Picture of Cutting the Boot Pieces
Supplies Needed:

Tools:
  • Boot Pattern
  • Scissors / Rotary Cutter
  • Cutting Mat
  • Pen (I used a metallic pen to show up on the black fabric and a black pen for the white fabric)

Materials:
  • Black Suede
  • White Vinyl Leather

I wanted the boot to be nice and thick so I used suede for the pieces. The suede gives it a nice look and you don't have to worry about the edges fraying. The piece I bought was about $20.00 and I still have some left over for a future project. I used white vinyl leather for the shirt details on the front and back.

Using my boot pattern I marked and cut each piece using fabric scissors and substituting a rotary cutter for all of my straight edges. 

Step 4: Cutting the Rubber Soles

Picture of Cutting the Rubber Soles
Supplies Needed:

Tools:
  • Sole Pattern
  • Utility Blade
  • Cutting Mat
  • Pen (I used a metallic pen to show up on the black rubber)
  • Bench Grinder
  • Safety Goggles
  • Mask

Materials:
  • Black 1/2" Rubber

I bought the rubber for the soles for $15 from a shoe repair shop.

I began by tracing my sole pattern onto the rubber pieces.

The rubber I bought was about ½” thick and was pretty tough to cut but I was able to cut the shapes out using a utility knife.

Since the edges were a little rough I used a bench grinder to smooth them out. I thought ahead and used goggles to protect my eyes from debris but did not think to wear a mask.....and my face was completely black! So don't forget to wear a mask, unless your going for a Darth Vadar look : )

Step 5: Sewing the Boot Fronts

Picture of Sewing the Boot Fronts
Supplies Needed:

Tools
:
  • Sewing Machine
  • Boot Details Pattern
  • Scissors / Rotary Cutter
  • Cutting Mat
  • Pen (I used a metallic pen to show up on the black fabric)
  • Binder Clips

Materials:
  • Black Suede
  • Boot Front pieces
  • Front Shirt Pieces
  • Black Thread
  • White Thread

Since the boot fronts were designed to mimic Han Solo's shirt I created pieces for the white shirt, the vest and added patches to look like the front pockets.

I began by sewing the patch pocket pieces onto the vest pieces. I used straight stitches and sewed very close to the edge, about 1/8" over. By attaching these first I didn't have to worry about sewing through 3 layers of suede once everything was attached. I used binder clips to keep them in place while sewing since the suede was too thick to use pins.

Once the patch pockets were attached I sewed the vest pieces to the front boot piece.

Next I attached the vinyl white shirt piece using white thread.

Step 6: Sewing the Boot Backs W/ Pockets

Picture of Sewing the Boot Backs W/ Pockets
Supplies Needed:

Tools
:
  • Sewing Machine
  • Rotary Cutter
  • Cutting Mat
  • Ruler
  • Pen (I used a metallic pen to show up on the black fabric)
  • Binder Clips

Materials:
  • Black Suede
  • Back Shirt Pieces
  • Back Boot Pieces
  • 2 Magnet Clasps
  • Black Thread
  • White Thread
  • Painters Tape

For the boot backs I continued the shirt design and added a little strip of white just like the fronts, and since I had some room I decided to add an actual pocket.

I began by sewing the white vinyl strip to the back pieces. I measured the position on the front to make sure the front and back pieces lined up.

I don't usually make a pattern for square pieces, so to create the pocket I used a ruler and measured out the size I wanted the pocket to be. I marked out the pieces in pen on the suede and cut them out using a rotary cutter.

I positioned the pocket on the back boot piece and used painters tape to keep it in place while sewing. Binder clips didn't work here since they weren't long enough to reach the position.

I used magnet closures for the pocket flaps and covered the exposed clasp on the top flap with a small piece of suede.

Step 7: Sewing the Heels W/ Labels

Picture of Sewing the Heels W/ Labels
Supplies Needed:

Tools
:
  • Sewing Machine
  • Scissors / Rotary Cutter
  • Cutting Mat
  • Ruler
  • Pen (I used a metallic pen to show up on the black fabric and a black pen for the clear vinyl)
  • Iron
  • Painters Tape
  • Binder Clips
  • Computer
  • Printer

Materials:
  • Back Heel Pieces
  • Boot Back Pieces
  • Black Canvas
  • Clear Vinyl
  • Black Thread
  • Iron-On Paper

For the back heel pieces I decided to add a Millennium Falcon label and make these look like real boots!

I used a Millennium Falcon image I found online and tweaked it a bit in Photoshop. Then printed out the design on iron-on paper for dark colors.

I used a piece of black canvas for the label base, and ironed on the labels.

I used painters tape to keep the labels in place while sewing them to the back heel pieces and used a 1/4" zig zag stitch to keep the edges from fraying.

Next I added a piece of clear vinyl to protect the image, using the same 1/4" zig zag stitch for the edges.

To complete this step I attached the back heel pieces to the back boot pieces.




Step 8: Creating the Belts

Picture of Creating the Belts
Supplies Needed:

Tools:
  • Sewing Machine
  • Scissors / Rotary Cutter
  • Cutting Mat
  • Ruler
  • Pen
  • Binder Clips
  • Painters Tape

Materials:
  • Boot Back Pieces
  • Brown Vinyl Leather
  • Black Vinyl Leather
  • Metallic Grey Vinyl Leather
  • Black Felt
  • Black Thread
  • Brown Thread
  • Grey Thread
  • 6-5/8" square studs
  • 74-1/4" square studs
  • 2 Magnet clasps


For the top belt I used a ruler to mark out a strip on the black vinyl leather long enough the wrap around the boot and cut it out with a rotary cutter.

I folded the piece in half and used binder clips to hold it in place while sewing.

Once the top belt was sewn together I marked out the position for the magnet clasp and area for the 1/4" studs. Then I began adding on the studs and ended up using 34 studs for each top belt.

Once the top belt was complete I attached one end to the back boot piece.

To create the bottom belt I used the the same process as the top belt, this time using brown vinyl leather. Once sewn together I began adding details to mimic Han Solo's utility belt. I added small patches to look like pockets and a fake Lightsabar with a few stud details throughout.

To finish off the bottom belt I added a buckle made from the metallic grey vinyl leather using black felt as a backing.

Next I added a small diagonal brown belt piece that connects from the heel to the belt buckle and sewed this piece to the bottom of the boot back pieces.

Step 9: Sewing the Boot Together

Picture of Sewing the Boot Together
Supplies Needed:

Tools:
  • Sewing Machine
  • Scissors / Rotary Cutter
  • Binder Clips
  • Painters Tape
  • Ruler
  • Cutting Mat
  • Pen (I used a metallic pen to show up on the black fabric)

Materials:
  • Boot Front Pieces
  • Boot Back Pieces
  • Suede Front Toe Pieces
  • Suede Sole Pieces
  • Suede
  • Black Felt
  • Black Thread
  • Grey Thread

Before I started sewing everything together I created some belt loops to hold the belts in place while being worn. I used a ruler and measured out the pieces on suede and cut them out using a rotary cutter. Once cut, I attached 1 belt loop to the boot fronts and one to the boot backs.

When sewing the boot uppers together I attached the pieces in the same sequence as I did for the boot lining. I used a 1/4" zig zag stitch for everything and sewed the pieces with the wrong sides together so the seams would be exposed. I used binder clips to keep the pieces in place while sewing.

I started the process by sewing the front and toe pieces together. Next I attached the front and back pieces together at the side seams. Then I finished by sewing on the soles. Attaching the soles was a bit tricky to maneuver through my sewing machine so just remember to have a little patience with this part, and don't forget that the force is with you :)

Once the uppers were sewn I added some felt binding around the entire rim of the soles. I decided to use felt since it looked fairly similar to the suede without having all the bulk.

Next I attached the lining to the boot uppers. I placed the lining in the boots, secured with binder clips, and sewed them together at the top opening. I added felt binding to finish off the top opening.

To complete the sewing portion of the boot, I attached the bottom brown belt and heel brown belt to the grey buckle piece.

Step 10: Attaching the Soles

Picture of Attaching the Soles
Supplies Needed:

Tools:
  • Clamps
  • Foam Brush
  • Heat gun
  • Saw
  • Screws



Materials:
  • Rubber Soles
  • Boot Uppers
  • Contact Cement
  • Painters Tape
  • 2x2 Wood Piece
  • 1x4 Wood Piece

The last piece of the puzzle...attaching the soles to the boot uppers!

To attach the soles I started out by taping the edges with painters tape to protect them from any glue spillage.

Next I began warming up the rubber soles with a heat gun. The contact cement adheres better in a warm environment and on warm surfaces.

Once the rubber soles were warm, I used a foam brush to apply a nice thick coat of contact cement to the top of the sole and the bottom of the boot upper. I applied the glue to one shoe at a time so the contact cement would stay tacky and pressed the soles and uppers together.

Once the soles and uppers were glued together I began the clamping process to make sure everything stayed in place. I used wood feet forms to apply pressure while the contact cement dried. I recruited some help for this part ; ) . They were created out of a piece of 2x2 for the legs and a piece of 1x4 for the feet. Once inserted the wood legs came right to the top edge of the boots and I was able to secure them down with a long clamp.

I then added on 8 smaller clamps around the entire sole and a medium clamp to secure the toe. Since the glue likes to dry in a warm environment I let them dry in the laundry room while I had some clothes drying in the dryer, yay to being resourceful!

 

Step 11: Wear and Enjoy!

Picture of Wear and Enjoy!

Wear and enjoy your new boots!

Comments

starwarsgeek1 (author)2017-02-12

this is such an awsome design! I am constantly running back to this thinking about doing my own pair

Username012 (author)2016-08-31

When I put them on my son comes and starts stabbing me with his kylo wren lightsaber

that is so sad... :(

R.I.P. Han Solo

whopoder (author)2014-01-30

Oh, it's really cool!

shizumadrive (author)2014-01-22

his belt has the same hexagonal design. He must have scrapped all the imperial decorations on them when he quit the navy. Or made the wookiee do it.

jparra6 (author)2014-01-21

simplemente genial

holidayv (author)2014-01-21

Nice instructable. Just to clarify, these boots are INSPIRED by Han Solo. These are not a recreation of the boots he wore, these are boots designed to look like you are wearing a Han Solo on your leg. Han Solo's boots are simple black leather.

General Zod (author)2014-01-21

Cooooooooooooool.

About This Instructable

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Bio: A person who enjoys making things!
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