This Instructable will show you how to build a suit of Clone Armour out of ordinary foam, cardboard, and duct tape. This particular suit was constructed for my 12-year-old step-brother, using an action figure as reference. A few pieces are missing (such as the hand guards, ab plate, and thermal detonator) but the look is definitely conveyed. From start to finish, this project took about a month and-a-half to complete. I can't accurately determine a budget, as I already had several of the materials on hand, but expect to pay $50+ if you are buying everything. Anyway, on to the steps!
Step 1: Materials
Interlocking Foam floor mats- Found at Home Depot and Harbor Freight Tools, comes in packs of four-$18 (you will need 2 four-packs)
Cardboard-Any will work as long as it's corrugated-Free!
Craft foam-Sold at most craft stores in 12"x18' sheets-99 cents a sheet
Plasti-Dip Spray-Sold at Home Depot-$6.95 a can-This build requires at least six cans
Glossy White Spray Paint-$4.48 a can-You will need about four cans.
Poster board or other stiff paper-For making templates
Duct Tape!-Also found at Home Depot and most craft stores
Elastic straps-Found at most craft stores
Heat gun-Used for shaping the foam
Hot glue gun+hot glue-Used to assemble the suit
Dremel-Used for relief details
(Optional) Latex caulking-Used to fill in the seams where the foam comes together. Gives a more "solid" look, but isn't entirely necessary