The RPF user Clothears – a.k.a. Alison Naylor – has been trooping as Boushh since 2006. Her costume was even used in the movie Paul. However, she did some more research on the costume used in Return of the Jedi and decided to craft a new version. She set out with the goal of making it as screen accurate as possible. Her and her partner built everything from the tunic to the helmet and discussed construction in great detail over at The RPF. Here’s what she said about the armor piece around the neck:
We moulded the armour from a 50/50 PU rubber and resin with a brown colour pigment. The mould was made to have imperfections in it, as the screen worn armour is very rough. It is very flexible yet holds it’s shape nicely and retains the sharp edges and fiberglass look that we would have lost had we gone with vac formed armour. Once the armour was moulded we trimmed it down and weathered it. Around the collar of the armour I have made the suede/foam padding and finished with the rough black stitching like the original. Also inside the armour is the velcro for attaching the leather tank strap, which runs from the two press studs at the top all the way down and attaches to the velcro inside the armour, we are pretty confident that this is how the original works. There is also velcro inside the front for the chest com link.
Read more and see additional photos at The RPF.