04 1/2" conduit Wood skewers Aluminum plate 14 ga. Purchase List (paid links): Black coveralls Chelsea ankle boots Black motorcycle gauntlet gloves Industrial safety gloves Face shield replacement EVA foam floor mats (4 pack) Craft foam Leather scraps Grey wool blanket Muslin perm press material Styrene plastic. This is a month of work, working most nights/weekends.
I used styrene depending on thickness of the item, including the hand guards and shin armor. I used a sharpie to transfer patterns to the foam, tracing around the paper patterns. Wait for the contact cement to dry completely before gluing. Wear a respirator! With foam being porous, you'll need two coats to prep it correctly. At some point you will be sanding through the pattern because you need a flat surface. While floor mats are the cheapest option, the EVA foam geared for cosplay can be nicer and doesn't have the imprinted pattern on the back. Everything else, I sketched a template on paper based on reference photos. I used Punished Prop's Mandalorian helmet template. I planned to work from head to toe, because the helmet is the most important part of the costume. I don't have time to sand/prime/sand for that perfect look.
Plus I know I don't want to pay for a good looking chrome finish like Alclad and it takes time to get an automotive quality finish. I like weathered and beat up props, and they're more fun to make. I worked from the helmet down, knowing that people would look at the helmet first and hoping they wouldn't look at the boots in case I hadn't finished them. There's a lot of parts and I never have enough time with Halloween being the due date. When I watched The Mandalorian I knew this year's Halloween costume. I've thought about making a Boba Fett Halloween costume for years.