Back in August 2002 I started on a project; to create my own Star Wars Imperial Stormtrooper costume from scratch. Now, nearly three years later, and countless hours research, trial and error reverse-engineering and hard work, I finally have reached a point where I have a complete set of armor molds done. I'm still working on the helmet molds, but for now the body armor is done.

A clone's armor is rugged and there is no need to show off its shine like a storm trooper. This option should only be for clone troopers. All of the rest of the characters are interesting to see how they are modeled so no paint jobs will be necessary for them. Re: Homemade Clone Trooper Armor Do you have the Butt plate PDF? I have been using your videos, trying to make my own armor. I started with card stock paper like people use for pepkura armor. I hoping not to run into your issues when its time to resin.

So, what does it take to make a stormtrooper costume? Well, the process is a complex one but not beyond what a fan can do in his spare time, and a few square feet in the garage. The first step is the vacuum forming machine. I must have made 4 different machines before I got one large enough to pull this project. The second step is the mold making. Different techniques have been used by other fans to make their trooper armor, but for me, I took advice from a fellow RPF board memeber, Phil G. aka Blaxmyth, and used MDF and Bondo to make the molds. Install ilbc codec asterisk. The final step is to pull the plastic, trim out the parts, fit, paint and weather.

This page details some of my efforts. A documentary short film is available on this process, on the companion site www.imperial-armor.com. Until that site is finished, most of my information [on how to make your own trooper armor] is kept here.

Here is a link for making replica hovi-mix mic screens

Here is a peek at the PVC pipe O2/Thermal detonator

Here is a peek at the PVC pipe Blaster

Here is the link for the template and how-to for the sandtrooper sniper knee diamond.

Here is a link to TKBIG's information on how he did his armor.

Brow/neck trim sites:
http://www.iboats.com/Flex_Trim_Black_3_16_X_25 not movie accurate, but nice neck trim material and will give your helmet a rigid neck
.
http://www.classiccar-trim.com Lots of options for both neck and brow trim.

http://www.mcmaster.com (Product #8507K41) for the brow.
http://www.sealsdirect.co.uk/bbCMS/shopping.asp?intDepartmentId=3#22 Product #US161 or US52 for the brow and SWR150 for the neck. These are screen accurate.

Disclaimer: I get emails all the time from people asking me to sell them armor kits. These are for a fan film, and not for sale. I'm not doing this project to make money, even though I need money to pay bills and buy diapers for the kids! Here is my thinking on this: First, the armor is not that accurate for most die-hard costumers wanting a screen accurate suit. [I'd say its good enought the fans/public that recognize them as Star Wars Stormtroopers, but thats it]. My molds will only last a few pulls, before needing repairs. I need to make about a 20 or so for a fan film. After this project will be complete, I do not plan to make any more. Email me for more details. I have always had a bad feeling about using someone elses ideas to make money from. I've been asked why go to all the trouble and expense to make the trooper molds, and a vacuum forming machine, and not offer to sell the parts. The answer is simple, this is my hobby, and I do this for my own enjoyment. I plan to produce a 'second' suit to be modified as a 'Sandtrooper'. After all, this is not about selling stuff, its about enjoying a fun hobby. If I got into trying to make a buck off this, that gets into legal issues with Lucasfilms. Something I don't want to do! For me, its about gaining knowledge, and a personal challenge. Can I do this? Is vac-u-forming really that hard? What else can I make? What will happen to the molds once I'm done using them? That I don't know yet. Most likely that will sit in the attic, collect dust and the grandkids can chunk them when I gone. I don't plan to sell the molds. I'm not sure how I'd feel if I sold the molds and later found out someone was selling 'MY' suits on ebay! What happens with the fan film suits once shooting wraps? I plan to give the suits to the actors in the film as 'payment' for being in the film and doing all the hard work. After all, the actors put days worth of work into pulling, trimming and fitting their costumes. What the actors decide to do with the suits will be up to them, but once the suits are out of my hands, I have no control over what becomes of them. Really, the way I'm making these parts, its going to be a low-cost costume solution, cheap enough for the fan film production, but not intended for the die-hard costume buff. Sort of my version of what I saw in the movies, and scaled to fit my lanky 6' 2' frame. The GT/FX suit is a little short. Also, since these are made from HIPs they work better for a dirty Sandtrooper, and not a clean and shiny Death Star Door Guard unless you want to paint the armor a glossy white, and add the proper knee plate! For the fan film, these will be mudtroopers with some underwater action, and some really beat-up looks to the weathering. For the nit-pickers, please try to remember, that these parts are fan-made in my tool shed, on a home-made vacuum form machine, one at a time, made by hand by me. They are rough around the edges, and need a lot of trim work before I ever get a suit I could wear! Each mold has hours of work in them, and there are 23 molds! If I were to calculate the time and effort I've put into this project, not just the cost of the plastic, I can't even begin to calculate the cost for each suit. Can't make your own suit and need to buy one? So far, Lucas has never liscensed a decent version of the suit or helmet, and thats too bad. The fan produced suits, however are very nice. Email me if you want to know anything else. Enough of the boring stuff, lets move on to the fun part!

date: 27.02.2012
author: sqeescesspent
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