This Boba Fett Lego costume, created by Dented Helmet member CGS1 for his 6-year-old son, is one of the more technically impressive cosplays we've seen in some time.
A graphic designer for almost 20 years, CGS1 spared no detail in the creation of the blocky outfit, which is all but indistinguishable from an embiggened Boba Fett minifig (From the 9496 Desert Skiff lego set, specifically. That's it in the top image, on the right, for reference.)
"The entire costume is built from scratch using photo references and scans I took myself," CGS1 writes at The Dented Helmet. "The costume is built primarily out of sintra with pink insulation foam used to carve the helmet dome and a small amount of plastazote foam used on the tips and base of the jetpack rockets." Which jetpack, it bears mentioning, is removable – just like the one on the minifig.
CGS1 goes into some detail on the design process over at The Dented Helmet, where you can see the project come together over several stages. Here's the first of three "making of" posts on the helmet alone:
All elements of this costume were approached the same way - photos, measurements, 2D drawings, scale, proportions. I used Adobe illustrator to hash out linear drawings of the helmet. Once I had the correct size of the dome, I was able to start. After a couple failed attempts at creating the dome with plastazote foam (making wedges to form the dome) I decided to carve it the old fashion way and simply used pink insulation foam from Home depot. Once I completed the dome, I began building the helmet using the antenna mount as my anchor point. I used a heat gun to shape and form the sintra, and glued layers to create the details throughout the helmet. After a few revisions ( the dark green concave section wasn't deep enough and I had to redo it) the helmet was ready for bondo glazing putty. I use this to fill the seams and rough spots in order to achieve a seamless plastic molded look, much like a Lego minifigure.
Excellent, excellent job. Many more details over at The Dented Helmet.
H/t Michelle!