Hey Tally...
I actually worked on this costume for the TFU release. While I never did finish it completely, I did work with the DXO over at Forcepike to iron some of the costumign bits down.
If this is something you are wanting to do, I can help you. We were able to figure what all the components were and what mods would need to be done to existing armor pieces. In a nutshell, this is a mix of storm trooper, Royal Guard and Jango Fett parts. Along with some custom pieces, including a unique ab plate, which I do have molds for.
I had a set of TK bells that I altered for this costume. I also have a tk chest plate that has been masked off with tape to reflect some of the subtle differences in the armor. I have pics up on my photobucket account. I'll shoot them to you, if you want.
As far as sintra is concerned, when Rick and I were doing to test runs on forming the ab plates, we found that sintra doesn't well for the ab plate. The detail is lost, when using sintra, and it doesn't look very good. ABS was used and it looked 10x better! Besides, some of the other costuming parts that one would be pulling from are usually ABS, anyway. Best to keep them as consistent, as possible.
Of course, sintra would work well for the back plate, gauntlets and the leg armor. Just something to consider.
Let me know if I can help you out, any.
- Bill