Photos and Video









*Updated 08/6/06*
Chroming:
The results are in and I'm very pleased!

The process is called "Vacuum Metalizing" and Vacmet.com located in southern CA Don Bies has confirmed that VMI is the shop that did the original C-3PO chrome suits for Lucasfilm. Kevin Franke at Vacmet charges $500 for as many pieces as can fit inside the metalizing chamber. The entire Threepio suit will fit in two chambers totalling about $1000. I've found that's a pretty typical price wherever you go.

You can read all about vacuum metalizing at StarWarsHelmets.com Jez has a great article on trying to get the perfect finish on his C-3PO helmets.

Article review:
Our opinions differ on the results. When you read the article, scroll about 2/3 of the way down and see Jez's "Comparisons of the Two Approaches" section. He prefers a less reflective, but consistent finish of the left helmet. I prefer the more reflective, imperfect finish of the right helmet. My opinion is that people aren't going to be examining your finish from 2 inches away. I'd much rather have the majority of the finish have crisp reflections even if there were a few small rough spots. rather than the all over, hazy finish.

Recommendation Update
M & M Metalizing in southern CA does NOT want C-3PO projects, so don't contact them. Last month I had recommended them, after they estimated $350 to chrome 35 pieces. After it arrived in LA the estimate jumped to $1500, then to $3500! They said it's just too much work. I apologize to those who followed the recommendation and called them. Mike at M&M said he got a ton of calls about C-3PO chroming.
Soft Parts:
For those "wearable" costumes, Here are a few items you'll need under the armor.

SHOES
Click here to search ebay for "Chinese Kung Fu Shoes". Daniels said he wore slip on shoes, and you'll want the lowest profile shoes possible. These shoes and fit underneath the screen-accurate shoe shells. C-3PO 's screen-accurate feet shells fit up to a size 9 foot.

BODYSUIT
Island Scuba
The dive skin that stormtroopers use also works for C-3PO . However, the only place you see it showing through is at the elbow and the back of the knees. You could get away with wearing any tight-fitting black clothing, as long as the knee backs, elbows and midsection show black and wires.

I also found that a Tummy Trimmer worn underneath the bodysuit helps keep your back supported and your tummy in.

HOOD
Island Scuba

*Updated 02/12/08*
GLOVES
I found glove liners work best for a snug fit. These are $3 a pair. Gr8gear.com

NECK
I cut out a thin piece of plastic (thinner that sintra or styrene, almost like plastic poster board) glued black foam liner to the inside and added velcro, then painted the plastic.

BELLY WIRES
I found ribbed rubber floor mat at the hardware store for sale by the foot. Don Bies said since AOTC they cast the mat in silicone for better flexibility and comfort. Black, wide wale corduroy will work as well for this prequel look. He also said they also used a lot of vinyl string in addition to actual wires.

I went by the craft store (Michaels, Walmart, Jo-Ann Fabrics, A.C. Moore, etc) and found an entire section stocked full of the vinyl string (also known as gimp, or plastic lace) in every color imaginable. The brand names are Toner Plastics and Rexlace. These will work for wiring and you'll be able to get the colors accurate! It's the same kind of string kids use to make beaded necklaces, keychains, etc. I got a bag of 12 different colors totalling 400ft. for about $4. This stuff is super cheap. It works well for the hand wires too.

Another idea which I ended up using is t-shirt puff paints applied directly to my black spandex shirt. I used blue, red, yellow, orange and gray. I also cut the pointy tip off the bottle so the "wires" would be the appropriate width. I'll probably redo my gloves like this too.

Machined Aluminum Parts
Russell has produced several parts in machined aluminum. For more info, contact him here: cambareng@hotmail.com He will cut the price if you order more than one piece. He makes the head antenna, eye grills and other parts for C-3PO.
See photos here:


Legs:
For keeping the knees together, I used the screw from the knee piston and added a screw/nut on the opposite side of the knee (I know, not accurate). Then I took small bungee cords, looped the hooks around the screws, tightened the screws, and stretched the cords up to the top of the thigh where there are grooves on both sides of the leg (just like they were made for it!) Anthony Daniels commented that that was almost exactly how his are done.


*Updated 05/16/06*
Newton Voice Amp:
The new "Newton" voice amp (about $45 shipped) is available by XtremeGadget. It's about the same size as the discontinued black Radio Shack amp and it's very effective. I would say this compares to the Radio Shack identically in performance. Comes with battery-charging capability.