Pretty Accurate Toddler-Size TFA X-Wing Pilot

[TerranCmdr]

Well it's that time of year again (Halloween) and since I'm not making a big costume for myself, I decided I wanted to make something cool for my son.
It started out, as all of these do, to make a 'simplified' version, but I get carried away. Plus, I already have all the plans to make the pieces correctly (from making my own costume), how hard could it be to just make them at 1/2 scale??

Started out with the jumpsuit. I had a decent amount of Solar Cherry stockpiled for my MKII suit so I dipped into that. I used one my kid's 2T onesies as a pattern, basically just traced around it on crumpled up paper. (Fun fact, my first pilot costume was based on an adult onesie pattern.)

I bought some 2" white ribbed elastic (or was it 1.5"? somewhere around there) and dyed it with RIT for the collar and sleeves.

Added a zipper and some simple pockets and the whole suit came together pretty quickly. Here's the first test-fitting. He likes it!

 

[TerranCmdr]

Added elastic to the arms, hemmed the legs, and sewed on strapping around the knees, and the suit is more or less complete. The strapping was insanely difficult to sew on. The Solar Cherry is thick fabric and the legs are so small that I didn't have a lot of space to work with. They're on there, just don't look too close at the stitching.

Moved on to the belt next. Bought some more strapping, it should have been black/dark grey but grey works just as well I think.

I started with the paddle parts. I scaled the pattern so that the slot fit the 1.5" strapping I bought for the base of the belt. I initially planned to cut it out of styrene but I didn't have any thin enough. I ended up coming across offcuts from my mudflaps for my car and decided I liked the material - it is strong but has some give. Traced and cut with a hobby knife (holes drilled), then sprayed primer and silver, finished with clearcoat.

I then had to figure out how I was going to make 1/2 scale roll pin buckles. I considered 3d printing, but I needed them to be strong enough to withstand my son running around and possibly tripping (he does that pretty often). I decided to fab them out of metal. I cut handles off paint cans and bent them over my pattern, then I got some thin aluminum sheet, cut and folded it over the bent wire, then drilled holes to make the slot and finished with a chisel. Looking at the real roll pin buckles, I didn't realize how accurate my construction actually was!

Once the hardware was complete, the belt was really simple to finish. I used some 1/8" chicago screws with holes made with a soldering iron, as well as some high-strength thread.

Test fit successful! He didn't want to take his costume off after this.

And one shot comparing to my full-size belt.

 

[TerranCmdr]

Got some work done on the vest.

I printed out all the patterns at 1/2 scale, they seem to be just about right.

Size difference vs. my vest, so cute!!

 

[SofaKing01]

Another "Parent of the Year" Award! Fantastic!

 

[TerranCmdr]

Another "Parent of the Year" Award! Fantastic!

Thank you! Means a lot especially from you - I've dug through hundreds of pages of your guys' Falcon build and it's so mind-bogglingly awesome!

Had him try it on with the vest and it's looking great!

(Yes that's a googly eye on his forehead, he's a weirdo just like his dad )

Printed out the chest box last night, will clean it up and throw some primer on it tonight. I used the Form 2 at work and a file I found on Thingiverse, scaled to 50%. We'll see if the size looks right when I take it home tonight. It feels super small but it's hard to judge the correct proportions without the rest of the costume.

 

[TerranCmdr]

Put in some more work on the vest... just a few things left to complete on it now. Sewing all the ribbing in is a tedious but enjoyable process. I got held up with the iron-on transfer as we have a laser printer now instead of an inkjet, so the printed iron-on was out of the question. Luckily we have a Silhouette, so I went with iron-on vinyl. It actually looks better than my vest. Add this to the list of things on this costume that look better than my full-size one.

 

[Too Much Garlic]

Ooh, I love creative people. Looks awesome.

 

[eethan]

This is pretty cool and well executed! congrats

 

[TerranCmdr]

Thanks guys!

All but finished the vest last night, I just need to add the circular part on the front to call it done. I also planned out the middle connecting piece, I plan to either sharpie or paint it instead of making a layered styrene cut like my full-size one.

I also primed the chest box and pulled out some LEDs I had laying around - might as well light it up!

And finally I did a little work on my own costume - took apart and primed my Black Series Poe helmet. We've got one week 'til the party we're going to so it's crunch time!

 

[TerranCmdr]

It's finished! Really proud of how this came out.

Chest box was painted up, clear coat applied (the most important step) and attached to the "buckle" that holds the vest together. I glued in a piece of aluminum with a nut and ran a screw from the back of the buckle part. For the hose, I grabbed some cowling off of my car that I used to cover the wires from some LED lights I put on. It just happened to be the perfect diameter.

I decided not to bother with boots or gloves as he wouldn't keep either on for long. His grey shoes look great with the costume though!

I have a helmet from a couple of years ago that I made out of paper. It came out too small but it fits him better than my full-size one!

Here we are together, ready to take on the First Order! (He even has snacks for the trip)

I managed to get base colors on my helmet, and slapped some stickers on. I need to go back and weather it and clean up some of the lines but I like how it's coming along. I was up until 1:30 the night before painting and masking. I actually wanted to go green this time instead of blue, so I might end up taking the blue back off and re-spraying.

 

[Krieger]

TerranCmdr, thats some real dedication! great costumes and nice work on the helmets. after masking and painting two of those black series poe helmets, I never want to see masking tape, plastic grocery bags, or paint ear cups again

Well done, and Happy Halloween!

 

[TerranCmdr]

Thanks! I used an exacto to get some decent lines on the masking but I'm not happy with it in a few places. I figure I can weather down anything that looks bad, lol.

 

[kickman88]

You guys look great!!!

 

[Kal Argos]

It's finished! Really proud of how this came out.

Chest box was painted up, clear coat applied (the most important step) and attached to the "buckle" that holds the vest together. I glued in a piece of aluminum with a nut and ran a screw from the back of the buckle part. For the hose, I grabbed some cowling off of my car that I used to cover the wires from some LED lights I put on. It just happened to be the perfect diameter.

View attachment 1078088View attachment 1078090

View attachment 1078091View attachment 1078092

I decided not to bother with boots or gloves as he wouldn't keep either on for long. His grey shoes look great with the costume though!

I have a helmet from a couple of years ago that I made out of paper. It came out too small but it fits him better than my full-size one!

Here we are together, ready to take on the First Order! (He even has snacks for the trip)
View attachment 1078093

I managed to get base colors on my helmet, and slapped some stickers on. I need to go back and weather it and clean up some of the lines but I like how it's coming along. I was up until 1:30 the night before painting and masking. I actually wanted to go green this time instead of blue, so I might end up taking the blue back off and re-spraying.

View attachment 1078094View attachment 1078095

Epic star wars Dad win!!!! Kudos!

 

[Krieger]

Two words. Galactic Academy!

 

[Kylo1]

How cool is that!!!!! Well done sir!

 

[TerranCmdr]

Well I got the Adam Savage stamp of approval so I'm happy. (ok happy is an understatement )