DIY Star Wars Costumes

Starting in on a Star Wars costume, Guavian Death Gang member (also called enforcers) from the movie The Force Awakens. When this costume is finished I will submit it for approval so I can wear it as part of the 501st Legion group I belong to. I am purchasing some items but almost all of it will be made by me from products anyone can purchase. DIY project!

Here is a 3D printed helmet I got in from an Etsy seller who offers printer services. I had bought the print files from another Etsy seller and then sent them over to the second Esty seller. The pieces are made from PEG plastic. It is tough and durable. I was a bit worried about other plastics that might deform in higher heat, like if I left the costume in the car on a sunny day.

I am told that PEG will sand smooth with wet sanding. I expect to be doing A TON of sanding and will let you all know how it goes.

I will also post who printed and provided the files.

Here is the lower front part of the helmet.

Flipped over the bottom of the same piece.

This is the top part, looking at the back.

Close up of the lines from the printer in the PEG plastic.

Now you see the inside of the top part with two round posts printed on the right and left sides.

Here is the top and bottom parts set together.

A shot of the back piece, with the chevron pattern.

Inside of the back piece, notice the thinned out areas in the print. Mistake, I think, but not a problem.

Side view of the back piece with a hole for that post to set into.

Here are the two pieces joined by the post. My understanding is that this was made this way so the wearer could flip the entire face part of the helmet up. Like a face shield on a motorcycle or snowmobile helmet.