Boba Fett
For Boba Fett, I experimented with reinforced plaster (heavy) and air-dry foam (light) only to find out how brittle they both are. A layer of Goop (glue) added to everything made it resilient despite the brittle core. Eventually I replaced most parts with 3D printed ones for better screen accuracy.
Camtono Cooler
I made a Camtono Cooler (and beskar safe) by modifying the TonyBlokeDesigns model and doing a little reshaping to fit it over a Coleman Poly-Lite cooler. The bottom was redesigned to be more screen accurate and to hold either 6 collapsible cups, or 2 cups and a secret storage compartment for the beskar I’m saving for foundlings. The electronics section is magnetically attached for easier removal for cleaning and battery insertion.
Carbonite Me
The carbonite "Han Solo"-like door was made for my man cave. It has a thermal detonator for the door handle. I also made a conversion kit to turn it into a full model - including side panels with electronics, which also doubles as a protective transport crate when reversed.
Dejarik Table
The Dejarik table was made with: 3D prints based on the Ian Martin files (Dejarik Builder's group on FB) with a few of my own modifications, a steel reinforced plastic pillar, a plywood base, a plywood intermediate level and an aluminum playing surface. For the electronics, I integrated an electronic piano and a few sound cards (Wookie and Klingon sounds) as well as switches for the lights.
Dr. Rhasiv
For Dr. Rhasiv, I modified a commercial Narkina suit with blue fabric paint, and added a drawstring and hidden pockets. I made a medical case out of a plastic one I had and assorted greebles (3d printed and found).
Grogu's Pram
The neighbours threw out a cat carrier backpack, so I turned it into a pram for Grogu. The lid was cut back a bit (too long) and the breathing holes were filled in with the piece I cut off + polyfilla. On the bottom I glued on a foam lip (slightly sanded to round the edges), and 3d printed the front white greeble, inner red trim and hinges. I filled the inside with leftover packing foam bits.
Jedi
I made the Jedi out of a Judo gi and some tea-stained fabric. The belt was made from leather, plastic tubes and other assorted bits. The lightsaber was a custom design, using the electronics from a toystore saber, modified so it can have a detachable handle.
R2-D2
R2D2 was made with 3D prints based on the Michael Baddeley files (v2) with an aluminum dome from Granite Earth. For the electronics, I integrated a frequency hopping radio transmitter/receiver, a Sabre, a Syren, an MP3 trigger and amp, chargers and am looking into an Arduino Uno and I2C servo controller to handle some of the more complicated gizmos. For the logic lights, I used LED belt buckles and for the PSI's I made some LED flashers. I also 3D printed a gold tray (from Jabba's Barge) and glasses.
Slave Leia
Slave Leia's bra and boot trim were made with air dry foam over formed metal wire (with Goop again). The bracelet and skirt plates were 3D printed. The staff and hairpiece were assembled from assorted scraps.
Willrow Hood
I dyed some orange coveralls to make them slightly less orange, and added a few pockets (with tools made from greebles) and a button to make my Willrow Hood costume. The wrist computer I 3d printed a design I modified to fit over an apple watch so it's still functional.
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