Tag Archive: Fett


How I Made my Boba Fett Costume

Lego Boba Fett Front

Here

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my

Blog

on

How I

made

my

Lego

Boba Fett

Costume…

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I work full-time, and attend College part-time.

I’m a creative Artist/ Sci-Fi geek/ Star Wars Fan who wanted a funny original homemade costume!

What can you make out of cardboard, paper mache’, tape, fabric, Velcro, hot glue, paint and a LOT OF TIME?\

JUST about the coolest costume EVER

My inspiration was a Star Wars mini-fig of Boba Fett.

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Inspiration LEGO Boba Fett mini-fig

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Here’s how I did it!

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For the HELMET OR HEAD…

I needed something that I could use as an armature that resembled a Lego Person’s head.

I found that an empty propane tank was perfect!

Paper Mache Propane Tank

First, I covered it with plastic wrap.

Then I watered down some Elmer’s Glue.

I dipped my newspaper in the glue-water, and began covering the tank, smoothing the paper flat.

After one or two coats I let it dry over night then repeated this application two more times.

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Cut out Eye space

Once dry I used a utility knife, and cut one long opening from top to bottom, then removed the paper from the tank.

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Then I cut a horizontal strip out for my eyes.

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Add a Temporary Spacer

I expanded the cut, to allow for the vertical slit in the helmet, and propped it open use a rolled up paper tube.

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Then I used more strips of paper mache to seal the upper cut section back together.

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I used a balloon to close up the top so that I could cover it with paper mache.

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Using a spackle knife, I applied joint compound (plaster) to any uneven or hollow areas.

Add Plaster - Sand Smooth

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Fill in holes with plaster - Sand

I let the plaster dry overnight.

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Finish Sanding and wipe all dust off

Then I sanded the plaster smooth with fine sand paper.

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Prime with quality primer

I cleaned the surface, and spray painted it with a quality primer.

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For the interior head rest, I hot-glued some Styrofoam on the inside, so that the cut eye slits lined up with my eyes.

Green Base Coat (3 to 4 coats)

I hand painted the helmet to match the Lego fig.

I used acrylic craft paint (purchased at Michael’s)

Tip:      Buy the closest color to your needs. I DO NOT recommend mixing your colors yourself. I used 3 bottles of this paint. Now after I have worn the costume, there is some minor damage to it. So I can easily touch up the paint chips, using the same exact pre-mixed color. Also, be sure to save extra for this purpose.

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Add other Paint Details

It was helpful to use painters tape in some areas.

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I attached, with hot glue, three layers of window screen on the inside; enough so that I was not visible from the outside.

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For the Hands:
I bought two 3″ PVC fittings (available at a Home Improvement store) and cut an opening in each one. Then I drilled a pilot hole at the back. I attached the 10 inch long wooded dowels with a wood screw. Then I primed and spray painted the hands with the same flesh tone color. I attached a white Velcro to the back of one hand.

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For the Gun:
I used found household items that would make up the shapes that I needed to match the Lego gun! When I could not find the right parts for the front of the gun, I cut cardboard circles and glued them together. I then filled in the hollow gaps in the cardboard with joint compound. Let dry, tape off, spray paint red & black, let dry, attached black Velcro to back of gun handle. Now the gun is removable!

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Making the Body & Legs:
Were a challenge to shape! Lego people are very short! Their body proportions do not match a person. Luckily I have access to a computer program where I was able to trace an image of a Lego figure and stretch it making it taller to fit me perfectly. This required a lot of measuring and planning. Then I had the correct length, width and height of each part of the body and legs! I started cutting up cardboard and used packing tape to attach it together. I also reinforced the corners with additional cardboard.

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Detailing the Legs:
I used my sewing machine, and covered the legs in gray cotton fabric and attached with Velcro. The circles where then painted on using acrylic craft paint. I attached straps at the top of the legs that attach to my belt so that the legs lift up when I walk.

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Hand Paint LEGO Body Details

Detailing the Body:
I used my sewing machine, and covered the body in gray cotton fabric and attached with Velcro.

I hand painted the front of the body’s fabric with acrylic craft paint using a photo as a guide.

All the cloth is removable and washable!

I use scraps of gray fabric to sewed two long-sleeves.

(You’ll need enough to cover your hands and hold the wooden dowels in.)

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The Jet Pack…

Create lightweight armature

I used recycled Styrofoam to create the basic flat shape of the jet pack.

I then used the flexible cardboard from cereal boxes to make the cylinders.

I paper towel tube and two small balloons were also used.

Before hot-gluing it all together I cut hole through the back and tied a string through the back.

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Paper Mache (2 to 3 coats)

I covered the entire jet pack with 2 to 3 layers of paper mache’.

I painted the entire pack green (3 to 4 coats to cover).

To attach the jet pack to the body I cut holes through the material and cardboard and tied it on.

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NOTE: My main goal with this costume was to get everyone who saw it to laugh and wonder who the heck is in there?! So none of me is actually visible when I have it all on! Which means? I can’t speak, or I’d give it away!

Adding sound:
I recycled an old birthday card that already had the STAR WARS theme song on it! At Radio Shack I bought a button and soldered it in place. I also bought a Digital Voice Recorder that will record and play 20 seconds of sound. I loaded up sound bites of Boba Fett from the Star Wars movies. I recorded the sound and then attached both voice players with their speakers and batteries inside the body of the costume. All of these parts are attached with Velcro, so they are removable and easy to repair!

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Lego Boba Fett - Finished

This Homemade Lego Boba Fett Costume took me 2 months to complete! I managed to keep it secret from ALL my friends. I threw a huge Halloween Party where I greeted each guest at the front door, in FULL costume, playing the STAR WARS theme and pointing my Lego gun at them. As you can imagine, everyone DID laugh and smile a LOT! Mission accomplished!

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Now my costume decorates one corner of my art room and inspires me to challenge myself everyday!
May the Force Be With You!

Good Luck making yours!

Lego Boba Fett - Finished

My Boba Fett Painting

Here are some progress photos… I started this painting in September of 2009… I will need to finish it soon! LOL!

My painting of Boba Fett_09-11-09 (16"x20" Acrylic on canvas)

My painting of Boba Fett_09-14-09 (16"x20" Acrylic on canvas)

My painting of Boba Fett_09-15-10 (16"x20" Acrylic on canvas)

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