This project marked my first experience undertaking a comprehensive costume build under a relatively short deadline. With the exception of the helmet and some in-progess 3D models, the entire costume was completed in about two and a half months! The goal was to debut the costume at Steel City Con in December 2024, coinciding with an appearance by Temuera Morrison (Jango Fett/Boba Fett).

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The armor parts were modeled in Autodesk Fusion 360, though some of the dents on various pieces were modified in Blender to achieve a more organic, screen-accurate look. While the helmet was already complete, the rest of the armor needed to be fabricated. All new parts were printed in SLA resin for speed and then backed with fiberglass for maximum durability. Every piece received a layer of texture using thinned body filler to match the surface of the screen-used armor. Due to the tight timeline, some of the planned armor parts and accessories were omitted to ensure overall completion by the convention date.

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Custom-mixed acrylics were used for the color application, and all decals were added using cut vinyl stencils. The paint was finished with a matte 2K clear coat, for durability, and a light pass of weathering.

Most of the soft goods were improvised due to the time constraints. The undershirt, short sleeves, pants, and gloves were off-the-shelf clothing items, modified to integrate with the costume. The flak vest and belts, however, were custom-made from scratch.

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All of the work described above was completed in-house, with the exception of the following: the aluminum gauntlet darts (MachineCraft Replicas), the chest display (KATSO Props), and the hand armor plate 3D models (Great Ape Studio).