How Do You Make A Star Wars Stormtrooper Costume?

An authentic, movie-accurate version of a Star Wars Stormtrooper costume costs thousands of dollars to create. Using the following steps, you can make the costume for a fraction of the cost and include the details that make it easily identifiable. Costume Step 1 Research the details of the costume in the "Star Wars Visual Dictionary."

Have several 3-D action figures on hand for reference. Build the costume to fit the body to avoid pinching and chafing. Step 2 Remove the collars from the PVC 90 degree-angle and split them lengthwise along the underside.

Use the heat gun to soften the plastic. Mold it to the shoulders, elbows and knees (See Resources). Step 3 Measure and cut the lighter gauge PVC pieces for the biceps and forearms.

Use Velcro to join the pieces to the shoulder piece and breastplate. File the cut edges to smooth any roughness. Add detail with the strip molding.

Step 4 Fashion the front and back of the torso from the two large white plastic trash cans. Connect the front ... more.

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