Re: Kid sized Jango Fett Costume WIP
I'm almost there! Only need to assemble the helmet and weather everything!
here are all the finished helmet pieces

Now on to the blasters! I first tried to make a mold using 100% silicon catalized with dish soap, I had read an Instructables about it and wanted to give it a try, it didn't go well. So I picked up some brush on silicon for molding, with a coupon it was only like $9 for a big tub. I just wish I wasn't in a hurry or I would have done about twice the coats. I would have also thought through the construction a little better as well, but oh well I guess I know for next time. As a side note masking tape isn't exactly the best mold jacket but it was fast and held the molds ridged.

I didn't have proper casting plastic resin but I did have polyester resin for fiberglass and Bondo, so I mixed small batches of 50/50 "Rondo" and slush cast these. After giving these a few hours and making sure they were cured I pulled the first part, and amazingly it wasn't bad!

The other 2 parts were a bit ruffer but at this point they will have to do.

After a little clean up I backfilled these with gorilla glue so the expanding foam would fill all the open area, good idea just don't over do it or you will have pockets of in cured glue that will come out at some point.
I then covered the pen ends and drilled a 5/8" hole in the center to allow the parts to attach to the 5/8" dowel that will go through the barrel.
and here it is assembled!

I came up with a unique holding fixture for these, a little tube with tape on the ends, and using the blasters to counterweight each other.

And here they are all finished!

Also the belt and holsters are done but I didn't get a picture. I'm excited to do the weathering tonight and call this one done!