How to Make a Stormtrooper Costume

If you’re wondering how to make a Stormtrooper costume, you aren’t alone. Ever since the first Star Wars movie was released in 1977, the shiny white armor of the Imperial Stormtroopers has been a popular costume choice.

White PVC pipe is a material used to make Stormtrooper armor.

In the Star Wars universe, Stormtroopers are the foot soldiers of the Galactic Empire and the personal army of the Emperor. They carry out orders without question and are an intimidating force. Stormtroopers were originally clones, but eventually, they were replaced by recruits.

One of the most distinctive features of Stormtroopers is their pure white armor. The outfit is comprised of 18 pieces and provides complete protection for the soldier. Other than markings for rank, all Stormtrooper armor is identical, adding to the uniform appearance of the force.

For the movies, the Stormtrooper armor was manufactured by Shepperton Design Studios. There were two different helmets produced: one for close-ups and one for stunts. Both designs were made of plastic, and they differ only slightly.

The white armor of the Stormtroopers is actually one of the most complex costumes from the Star Wars movies. Making your own Stormtrooper armor will be a much more involved process than creating a Darth Vader costume or a Jedi outfit. However, if you have the time to devote to this project, the end result will be well worth the work.

The Internet is an excellent source for Stormtrooper armor tutorials. You’ll find instructions for costumes with varying degrees of complexity and authenticity. Take a look at the options, and consider these questions when choosing the right tutorial for you:

• How much time do you have to devote to your armor project? If you’re not in a hurry and want an authentic reproduction, you’ll probably want to create one of the more elaborate versions of the armor.
• How handy are you? Some of the Stormtrooper costume ideas involve power tools, and most involve some sort of heat source. You’ll need some basic skills, as well as a place to work.
• Is authenticity important? If you just want the look of a Stormtrooper outfit, you may be able to get away with a simpler design. However, if you’re planning to wear this to a convention or are a die-hard fan, you may only be happy with an authentic reproduction.

Take a look at all the options for Stormtrooper armor before you settle on the one that’s best for you. Most instructions include images or diagrams, and at the very least, you’ll see a photo of the finished product.

• Studio Creations calls their guide the "Definitive Stormtrooper Costume How-To," and they have every right to that title. Here, you’ll find information about making body molds, vacuum-forming plastic, and properly sculpting the armor. This site also sells a kit to help you make your armor, and this may be a good investment for beginners.
• The site of a fan filmmaker, TK560.com has some great insights about making your own armor. The Stormtrooper costumes look accurate and convincing, and this site is a valuable resource for making your own costume. You’ll find tips about molding plastic, as well as information about making Stormtrooper accessories.
• TK-899’s White Armor Chronicles is another great source for an in-the-trenches look at creating your own Stormtrooper costume. Since 2002, the site has been dispensing wisdom about all things armor-related, and there is a wealth of information about modifications and accessories.
• For another great armor-building resource, check out TrooperArmor.com. This site even includes a flow chart to help you decide how you want to create your Stormtrooper outfit. There are instructions for plaster molds and wood molds, as well as a comprehensive materials and supplies list.

Although it is an involved process, you’ll find you get an added sense of satisfaction if you learn how to make a Stormtrooper costume. This project requires special skills and lots of time, but the results are truly spectacular.

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