We first brought you this Lego Boba Fett cosplay last month, but now we have details on how it was constructed. It was built by The Dented Helmet member CGS1 for his six-year-old son. CGS1 has been a graphic designer for 20 years and decided to replicate the Lego Boba Fett that was featured in the 9496 Desert Skiff lego set.
He wrote extensively about the build process over at The Dented Helmet saying,
“The entire costume is built from scratch using photo references and scans I took myself. The costume is built primarily out of sintra with pink insulation foam used to carve the helmet dome and a small amount of plastazote foam used on the tips and base of the jetpack rockets.” Which jetpack, it bears mentioning, is removable – just like the one on the minifig.
It’s really incredible the amount of thought and dedication that went into making this costume perfect for his little son.
All elements of this costume were approached the same way – photos, measurements, 2D drawings, scale, proportions. I used Adobe illustrator to hash out linear drawings of the helmet. Once I had the correct size of the dome, I was able to start. After a couple failed attempts at creating the dome with plastazote foam (making wedges to form the dome) I decided to carve it the old fashion way and simply used pink insulation foam from Home depot. Once I completed the dome, I began building the helmet using the antenna mount as my anchor point. I used a heat gun to shape and form the sintra, and glued layers to create the details throughout the helmet. After a few revisions ( the dark green concave section wasn’t deep enough and I had to redo it) the helmet was ready for bondo glazing putty. I use this to fill the seams and rough spots in order to achieve a seamless plastic molded look, much like a Lego minifigure.
See more pictures after the break.
Read more about the design process over at The Dented Helmet.
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