Star Wars Clone Trooper Costume
Probably one of the more challenging craft projects I've undertaken with the kids, to fabricate a childs full Clone Trooper costume (including helmet) from rigid boxboard sheets. Below is the end result and a bit about how it was done.
Dear Stars Wars fan
To all died-in-the-wool Star Wars enthusiasts, arriving here thinking to find an authentic how-to-build Clone Trooper armour guide with accompanying proportions perfect templates, my apologies.
“Aren’t you a little short for a stormtrooper?”
This was built to fit a ten year old, so unless you're vertically challenged, I wouldn't recommend duplicating it.
It's also far from proportions perfect; I was working from photos. Therefore, what you see here is a fair-to-middly replication of a very short Clone Troopers set of armour... made of cardboard... and a few other bits and pieces that I could find in the garage.
That said, it ain't half bad (even if I do say so myself), and I hope you'll appreciate the effort, and at the very least give the 'Awesome' button on the bottom of the page a big thump; before leaving to find the genuine article you failed to find here.
And may the force be with you in your search.
Before you leave, let's listen as the troops play the opening of the imperial march; hum along with me: dum, dum, dum, dum-dum dum, dum-dum. Dum dum dum, dum, dum da-da... etc.
So, how did I do it?
This sort of project takes planning. I started by viewing a lot of Clone Trooper outfits online, downloading detailed images for reference and working out measurements.
These measurements I then scaled down to my sons size.
Using those measurements, I fabricated basic frameworks around which to build the armour. Some pieces didn't require this, however, pieces that encircled a part of the body were best assembled around a frame; this helps maintain symmetry. All framework was fabricated from the same cardboard as the costume.
A bit about the processClick thumbnail to view full-size
The finished outfit took a pile of pasted boxboard (cardboard) that reached my waist. I think that's over 200 sheets; each sheet 200x280mm. The boxboard came in two grades, 1800 and 1400 gsm.
Other materials included:
- Glue (heaps of it); including craft and PVA glue, hot glue and super glue
- Super fine filler (I used Nordsjo Super Filler)
- Foam padding
- White and black fabric (stolen from my wife's sewing basket); used mainly as a backing to give strength to cardboard
- Velcro; for connecting and holding all the parts in place
- Misc: rivets, clear plastic for helmet, LED lights for helmet, various plastics bits, vinyl.
- Lots of white spray paint!
Any job is made easier when using the right tools, and I would go as far as to say that with projects such as this, they are a necessity.
For this project I used the following tools:
- Razor knife (absolutely essential), with lots of spare blades; you'll need them.
- High revolution rotary multi-tool (these things are a godsend)
- Quality craft shears and a range of scissors
- Range of paint brushes from fine to 25mm
- Sharp pencils and a few dark felt tip pens
- Range of sandpaper grits
- Self healing cutting board
- Putty knife or equivalent
- Craft clips and/or pegs
- Stainless steel rule
- Safety glasses
- Spray bottles
- Duster brush
- Dust mask
- Rolling pin
- Rivet gun
- Glue gun
Serious CraftClick thumbnail to view full-size
As this project proceeded, my work area expanded; until what started at the kitchen table required reorganising the garage; half of which became a Clone Trooper manufacturing facility.
There are over twenty individual pieces, and at times I was working on half a dozen simultaneously. While the glue dried on one, I cut, folded, rolled, assembled, sanded, painted the others. It's a project that just got busier.
That said, it was also a great time spent with the kids. Both of my youngest children (8 and 10) moved their craft tables into the garage, and we spent many hours together; even moving in one of the lounge sofas so we could hangout in comfort. By the end, the rest of the house became neglected, my wife taking up residence on the sofa, and even meals eaten there... it was great!
So, although it took a lot of planning, patience and time, the upshot was quality/quantity time spent with the kids (and wife), a great gift for my son, and a sense of something worthwhile accomplished.
Downside... now my daughter wants one... so its back to the garage... has anyone got any more cardboard :)
I'll most likely expand on this hub as time goes by, more detail on the process; I just really wanted to post the hub and share the awesome photos.
- How to Make a Child's Clone Trooper Costume from Cardboard
Probably one of the more challenging craft projects I've undertaken with the kids, to fabricate a childs full Clone Trooper costume (including helmet)...
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