We always recommend using curved cut materials more as they will shape around shoulders when glued up. For this part of the costume, we used three pieces of foam with curved cuts. We used a Dremel and a sanding block to round all the edges more. As for the chest plate, we used craft foam with a floor mat backing. Doing this process may sound tedious, but it improved the accuracy of the size and even color, leaving little to no room for error. We attached the pieces we have created, fitted them to our model, and then took a picture. We always suggest that you measure twice, if not more, before cutting once. We did this before transferring the design. We traced the template on a poster board in order to fit the parts to our model’s body. Like the helmet, you’ll also need a template to cut out the parts of your chest piece. We used contact cement again to stick it to the helmet. Before doing this, we strictly recommend using a respirator because it is porous, which needs two coats or more. We also used contact cement to glue them piece by piece.
Since we wanted a clearer look, we sanded out the edges. Using the hobby knife, we carefully cut out the parts for the back and side. Afterward, we transferred the markings on the foam using a marker. We used the Jango Fett template design and sketched it on paper. It was also easier to cut and design, even for the back and side parts. When we made a Mandalorian Mercs helmet, we used EVA foam, which is somewhat cheaper than other materials. There are downloadable helmet templates found in the Mandalorian Mercs costume club, which may help you sketch the design. Lots of Star Wars fans often start with building the helmet piece. You may also need a pencil, marker, scrap paper for protecting your work surfaces, duct tape, hobby knife, cutting mat, hacksaw, and file. Depending on your chosen materials, you may also need heavy-duty glue, glue gun, or any form of sticking products to put the armor parts together. Consider how much you’re willing to pay and save, too. You may choose foam, cardboard, or even metal. Gather Your Tools and Materialsīefore starting, we suggest that you gather all the tools and materials you need in making armor. We have downloaded Boba Fett armor templates in the Mandalorian Mercs costume club, an LFL, and Disney charity costuming group. Recreating the pre-Beskar armor isn’t that difficult to learn if you have the resources and materials. 7 Easy Steps to Follow When Making A Mandalorian Armor With the “force” on your side, it’s actually pretty easy.
However, to actually learn how to make a Mandalorian armor is too challenging-says the person who hasn’t read this simple how-to. Well, if you’re a cosplayer, you won’t need a special day to wear this most coveted costume. Star Wars fans always rave about wearing the perfect Mandalorian armor whenever Halloween is coming.
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