That's cool.
If you don't have a 3D printer then cardboard is your friend.
Cardboard pipboy:
https://www.youtube.com/watch?v=jviTDRQUDWc&feature=youtu.be
http://www.therpf.com/showthread.php?t=91927
Cool ranger helmet over here too:
http://www.featherweightcreations.com/2014/06/05/ncr-ranger-helmet/
If you have some time (like from now to Nov) you can probably get at least one of these made with trial and error (and cardboard). It's not hard it's just about patience and having a willingness to mess up and then try again.
A cardboard pipboy could also be custom fit to any phone and it'd look as good as your paint job - which is potentially better than the one that ships with the game. It won't survive rough handling but neither will the plastic one.