| BOBA'S ARMOR |
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| This picture shows the eleven pieces of Boba Fett's "flat" armor, traced out on a 4' x 4' sheet of Sintra plastic, which is 1/8 inch thick. By tracing the patterns this way, we can actually get two complete sets of armor from this one sheet of Sintra. We use this type of plastic not only because it is inexpensive and easy to work with, but it can also |
| be shaped by emersing each piece in boiling water (for only 15 seconds!). Once the shaped pieces have cooled off, they will hold their shape and are very strong. |
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| After all of the pieces were traced onto the Sintra, we cut them out with a Jigsaw. Next, we sanded and deburred each piece using a beltsander (as you can see Brian doing to the left), 100 & 150 grit sandpaper, and a medium sized file. We also used a Dremel tool to smooth out some of the harder to reach areas, such as the slots in the knee guards. All of the pieces were now ready to be shaped, so we boiled some water in a large pot and started to emerse the armor, piece by piece, into the water for about 10 - 15 seconds at a time. Each piece had to be shaped quickly then run under cold water to "freeze" it into shape. |
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| Once the pieces are shaped, they are ready to be painted. Brian used Rustoleum Hunter Green spray paint for the chest armor, neck piece, cod piece, and backplate. He used Rustoleum Sun Yellow spray paint for the shoulder and knee pieces. For the scrape marks, he brushed silver paint onto the pieces with a sponge. For the blaster marks, he first used a Dremel tool to |
| gouge out the marks, then he added the paint effects. |
| For more pictures of the finished product, visit the Gallery section. |