Introduction: Adult Storm Trooper Costume

Picture of Adult Storm Trooper Costume

In this how to I will show you to create a adult storm trooper costume using leftover cardboard boxes, Fiberglass cloth, resin and paint.

Other resources which were invaluable can be found here.

this is my first instructable be kind.

Step 1: Research.

The Storm trooper costume is a classic, I had always wanted to purchase a suit for myself, but since they can cost in the thousands of dollars for a quality replica I opted to make mine on the cheap. 

I started with research. Couple of sources which were paramount and I think tipped the scale in finishing a difficult project like this.
This first link provides detailed measurements of all pieces which create this costume.  They deserved a shout out.
The second which is by the author HIREROB details a childs version of the costume.

Step 2: Materials and Tools

Picture of Materials and Tools


Cardboard - as much as you can get.
Fiberglass Resin - about 1 1/2 gallons.
Fiberglass Cloth - about 4 packs
Fiberglass all purpose filler.  1 can
Bottle of contact cement.
Box of 5/8s drywall screws
white spray paint.
Painters tape. - 3 rolls. Blue or tan.
white Electrical tape - roll
Cheap throwaway grade paint brushes. - for use with Resin
White zip ties. - Not red. X)
Nine cents in pennies.


Metal snips.
Sharpie marker
Razor / utility knife.
Extra blades.
Cheap throwaway grade paint brushes. - for use with Resin

Other items

Black sweats
Black jersey gloves
Black turtle neck shirt.
Cement boots from homedepot
Lots of time.
One patient friend about 6 feet tall.

Other safety items which could be included.  A paint respirator, some Nitrile or Latex gloves, and Safety glasses.

Step 3: Creating the Card Board Forums.

Picture of Creating the Card Board Forums.

I have only included basic paper templates which I had scribbled into a notebook, I exploded these into full size pieces after taking detailed measurements of my body. After exploding these onto my cardboard each piece was hand rolled with the corrugations, this left my cardboard blanks flexible and in the basic contours of my body. Symmetry isn't really my forte so be kind and use your imaginations when cutting and creating your own templates. 

And yes I spelled pieces wrong on purpose :P.

Step 4: Applying the Fiberglass

Picture of Applying the Fiberglass

After bending your pieces to the correct shape, use screws, pins and tape to keep the basic body curves.  Once you apply your fiber Glass cloth and resin you can remove these binding materials.

On the shin guards and forearms. I created them in one piece and ended up cutting them in half.

The pictures below are the left and right Forearms.

Now this was a helpful I found that after fiber glassing the outer parts the surface was left extremely stippled.  I overcame this by applying a layer of painters tape over my fiber cloth after it dried, then laying another layer of resin. which left me with a passably smooth surface.

Step 5: Creating Costume Details.

Picture of Creating Costume Details.

This was one of the hardest parts. 
If you take the time to view the studio creations website there is a number of intricate details which these armors have that goes missing under the pass of the movie camera. 

Like any cardboard work project the details again were added using cardboard. 

The chest piece, knee, Groin, and shoulders and belt are just stacks of layered cardboard, cut to appropriate size using a utility knife. Then using painter I like the exposed edge which hid all the corrugation and applied my final layer of fiberglass resin.

These layers were glued together using contact cement, and Alex plus white caulk as a filler for joints.

For any details that required ribbing I simply peeled away the first layer of cardboard and exposed the corrugation.

Step 6: Sticking the Whole Project Together.

Picture of Sticking the Whole Project Together.

Now Alot of my friends asked HOW the firetrucks was I suppose to get this to stick to my body.....  Simple using multiple contact points and industrial strength Velcro.  each part interconnected using small strips of Velcro painted white to match the costume.

Most of the costume bulk is support by the abdomen plating, and chest and back plates.  Pieces such as the thighs were supported through large velcro pads attached to the belt,  which in turn was connected to the abdomen via Velcro strips.

Parts such as the shin guards, and forearms supported themselves

Step 7: Final Results.

Picture of Final Results.

The final results were something that was a little rougher then I was happy with. so the close up scrutiny of the costume came with a great deal of criticism.  at about 10 feet the imagery was impressive and as you can see the pictures look pretty bad-ass.

If anyone has any questions feel free to post.


itsmeandu11 (author)2017-07-20

Yea, great job! I was just curious, how much did you pay for all of the supplies?

lisad181 made it! (author)2016-10-06

incredible! much obliged to you for the tips it is utilize full for me since this Halloween i m wanting to cosplay Stormtroopers. i m greatest enthusiast of Stormtroopers, i played its amusement that is truly wonderful. i purchased stromtooper bracelet its look beautiful,i put my everything essential keys in it ,you may purchase this from amazon.

YaelT2 (author)2016-10-05

Now, im started mine clone

!!! you are my inspo!

IsaacB49 (author)2016-09-21

Would paper mache work as someting to make it sturdy

NakedS1 (author)2016-05-15

Where did you get the helmet?

SpidermanHero124 (author)2016-03-26

how much is the total cost of you costume?

Stickman939 (author)2015-12-21

I've a couple questions.

First off, how do I measure out my body for the parts

And is the resin absolutely required, or is there a cheaper alternative to it? (Cause I don't want to put too much money into something that might flop)

TheGreatCoon (author)Stickman9392016-01-13

I didn't use Resin when I put mine together I just formed cardboard to the shape that I wanted and super glued it all then I spray painted it and it worked fairly well obviously it only lasted for the day I needed it too it could have lasted longer if I hadn't chosen to tear it off but resin would be great for making it look more realistic like the movies

TheGreatCoon (author)2016-01-13

So I made a Suit out of Cardboard for the new movie it wasn't Beautiful but it worked for the night and still turned a few heads I used this as a great tool to reference for building it and it only took me about 2 days to do what I did have anyways I am building a better one over the next few weeks for Great Lakes Comic con and this will be used again thanks for posting this I really appreciate it

BoromirO (author)2015-12-04

This is awesome! I'll probably use this same techniques when I start to make a Cyberman costume!


matthew.bartz (author)2015-04-25

How much did this cost you? I am thinking of making one of my own.

StephenYellow00 (author)2014-10-03

This looks great. I will end up making something similar when I stop growing.

nickwrdlw (author)2014-07-03

I started to make this same thing. I covered my cardboard in wide strip scotch tape pretty much. If I cover this with bondo will the bondo stick to it? and if not can I get the bondo to come off in one piece, like a mold pretty much??

Running Wolf (author)2014-06-27

Thanks for posting this. I saw some guys at the zoo (Zoo Boo @ the Erie Zoo) last year with some Clone Trooper Costumes.

I might do a few things differently but you have a really good concept that makes it easy even for an idiot like me to make something this awesome.

Sebastians (author)2013-04-04

Magastik armor and cool job dude

Darth Caius (author)2012-12-06

But wouldnt you have to mould it?

Darth Caius (author)2012-12-05

Dude you've done a great job the only thing is im to young to use fibre glass could i use something else

Railes (author)Darth Caius2012-12-06

Craft foam works well.

nof-z (author)2012-10-06

if you are using fiber glass and you want it smoother, just sand it down, and if you reach the base, just apply more resin.

jiangpanda (author)2012-07-28

If you do this and it doesnt look too good, just scuff it up and make it look dirty and say it was a battle.

craftsmith (author)jiangpanda2012-08-27

either that or add an orange pauldren, really scuff up and dirty and claim you are a sand trooper........

Railes (author)2011-11-01

I would approch a few things differently. Soaking some my cardbord, then bending would have been my first thought. Like for instance the calves or buttocks, doing that I believe would alow the parts to find a more natural looking curve.

The second thing would be to spend more time sizing the suit. It can pinch and rub on the legs, after a night of walking can be frustrating.

I had a thought of doing a kydex casting, this would alow me to make the suit into a plastic replica. Giving me the durabilty cardboard would never have.

Lastly making the buttocks and lower back into one peice instead of seperate.

parrster (author)2011-11-01

Great job. After fabricating one of these suits for my son, I can appreciate how challenging the task is. If you made it again, what would you have done differently?

monsterlego (author)2011-09-22

"These aren't the droids your looking for"

SkidinDINGO (author)monsterlego2011-10-28


salocin111 (author)2011-10-12

If anyone is interested in tackling a DIY stormtrooper helmet, this might interest you
it's quite labor intensive though
and to save you some time here's the direct pepakura printout link (missing tabs though)

tinker234 (author)2011-09-30

at the plummer store there is that ringed stuff like storm trooper stuff

shawnlambert (author)2011-09-19

Was the helmet store bought?

Railes (author)shawnlambert2011-09-19

Yes. It is a efx replic helmet. I tried many times to recreate the helmet
Without papercraft it was hard and i didnt have a mold to use. So the rsults looked something handicapped.

Spycrab (author)Railes2011-09-29

That's pretty funny, as the reason I came here was to see how to make a helmet as the thumbnail looked promising XD Still, awesome instructable, I may get around to making this, as halloween is pretty soon. :3

mrmerino (author)2011-09-22

I love that dog's face in the second picture.

The Papier Boy (author)2011-08-14

For the materials used and budget this is excellent. It's a really nice instructable. Some of the photos are too small which I assume is because they were taken with a phone??? But it's great overall.

atombomb1945 (author)2011-08-08

I think it looks great. Anyone who criticizes your work are probably people who have never tried to do something like this.

Railes (author)2011-08-05

I decided to make the instructable about a year after I made the costume, something I always wanted to do. I only wish I had take more pictures and saved more of the materials for the constructions; I would have been able to provide alot better details. But alot of parts were scrapped and re-made.

TekoMuto (author)2011-08-05

you seem to be a lil short for a storm trooper :/

(great job btw XD)

splazem (author)2011-08-05

This is AMAZING!

About This Instructable



Bio: I eat food, sometimes I'm funny.
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