Custom Mandalorian Flight Suits
What We Build
Flight Suits & Soft Goods
Custom flight suits, flak vests, neck seals, kama, capes, gloves, and other soft parts built to your measurements and designed around your armor.
Armor & Helmets
Custom armor sets, helmets, gauntlets, jetpacks, and other hard components designed for your character, color scheme, and build requirements.
Blasters & Props
Blasters, holsters, accessories, and character-specific props made to complete the look and function of the costume.
Full Mandalorian Builds
Complete custom Mandalorian costumes built as one cohesive system, from the flight suit underneath to the armor, weapons, and final finish.
Whether you're pursuing Mandalorian Mercs Costume Club approval, creating an original Mandalorian, or building a character inspired by the Star Wars universe, every commission begins with your measurements and your vision. We build each project from the ground up, balancing screen-inspired aesthetics, comfort, durability, and craftsmanship so your costume looks incredible and feels great to wear.
Tailored to Your Measurements
Every pattern is drafted and fitted for your body.
Premium Materials
Professional fabrics, leather, hardware, and construction techniques built for years of wear.
Designed to Work With Your Armor
Soft goods, armor, belts, holsters, and accessories are designed as one complete system.
Handmade in Colorado
Every commission is designed and built by Todd & Katie at OuterRim Creatives.
Built Right for Those Who Know What’s Right
Why OuterRim Flight Suits?
Built Around Your Kit
Your flight suit isn’t created in isolation. We account for your chest armor, gauntlets, belts, knee pieces, boots, and other components so the finished suit works with the full kit. Before construction begins, we’ll review your references and talk through how every piece needs to fit together.
Custom Patterned
Every flight suit is drafted and fitted to your measurements instead of being resized from a stock pattern.
Built for Armor
Every seam, pocket, closure, and reinforcement is designed to work with your armor and movement.
Club Ready
Whether you're building for the Mandalorian Mercs Costume Club, the 501st Legion, or your own original character, we build with approval standards and durability in mind.
Made in Colorado
Every commission is handcrafted by Todd and Katie, one client at a time.
Frequently Asked Questions
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Absolutely. We regularly build custom flight suits for members and applicants of the 501st Legion, Rebel Legion, and Mandalorian Mercs Costume Club, as well as for clients creating original Star Wars characters.
Each organization and costume has its own Costume Reference Library (CRL) requirements. We build your flight suit to match the specific standards of your character while tailoring it to your exact measurements for the best possible fit, comfort, and appearance.
If you're pursuing club approval, we'll work with you to ensure your flight suit supports the requirements of your specific costume.
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Our custom Mandalorian flight suits start at $850 for a basic set that includes the shirt, pants, and flak vest. If you'd like us to sew in the Velcro for your armor, that service is available for $100.
No two Mandalorian flight suits are exactly alike. Different characters and costume standards call for different fabrics, quilting patterns, seam layouts, closures, pockets, colors, and construction techniques. Those details all affect the time required to build your suit.
Every commission is quoted individually, so you'll receive a detailed estimate based on your specific character and build.
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Absolutely. Every flight suit is tailored to both your character and your body. Whether you're recreating a screen-accurate design, building for club approval, or creating an original Mandalorian, we customize the fabrics, quilting, seam layout, pockets, and construction details to match your vision.
Just as importantly, every flight suit is patterned to your exact measurements, creating a fit that's comfortable under armor and built specifically for you, not altered from a stock size.
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No. We can build your flight suit whether you already have armor or you're starting from scratch.
If you already own armor, we'll tailor your flight suit to fit and function with your existing kit. If you're planning a complete Mandalorian build, we can design and build the flight suit, armor, belts, holsters, and accessories together so everything works as one cohesive costume.
Either way, your flight suit is custom patterned to your measurements and built specifically for your project.
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Build times vary depending on our current production schedule and the complexity of your commission. Typically we ask for 6 weeks, but we'll discuss your timeline during your consultation and provide an estimated completion date before work begins.
If you have an event or convention deadline, let us know as early as possible so we can determine whether your project can be completed in time.
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A custom flight suit is built specifically for you. Every pattern is drafted to your measurements, every detail is tailored to your character, and every component is designed to work with your armor.
The result is a flight suit that fits better, wears more comfortably, and becomes the foundation for a Mandalorian costume you'll be proud to wear for years.
Ready to Build Your Mandalorian?
Whether you're recreating a screen-accurate character, pursuing club approval, or designing an original Mandalorian, we'd love to help bring your vision to life.
Every OuterRim flight suit is handcrafted to your measurements, built around your armor, and made for years of conventions, troops, and adventures across the galaxy.
Every Mandalorian tells a different story, and every flight suit should reflect it. At OuterRim Creatives, we handcraft custom Mandalorian flight suits tailored to your measurements, your armor, and your vision. Whether you're building for the Mandalorian Mercs Costume Club, the 501st Legion, or creating an original character, every suit is designed for comfort, durability, and the level of craftsmanship serious costumers expect.