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
Couple of question here first, how tall is your step-brother? Is the back piece to the chest armor the same cut out as the front apart from the "pecks?" Thanks in advance!
My step-brother is between 5'1"-5'2". The back piece is a seperate cut-out. As you can see in the pictures, the front piece curves upward on the bottom so he can bend at the abdomen.
Can you only make it that size
It can be made at any size. All the patterns were free-handed.
<p>The armor looks good keep up the good work!</p>
<p>Hello, </p><p>I was wondering, what would I use to harden the plastic? </p>
<p>Hello,</p><p>We would love to feature your project on our website, DipheadsUnite.com. Would we be able to use your image? We would give you a shoutout and link back to your blog. Please let us know. </p><p>Thanks,</p><p>Plasti Dip</p>
<p>I would be honored to be featured! You have my full permission to use my image, though I regrettably lack a blog.</p>
<p>This is awesome! Great job!</p>
<p>So I use Plasti-Dip to harden the foam, and then I can paint it the required colours. Is that right?</p>
The Plasti-Dip doesn't harden the foam, it simply seals the porous surface. But yes, after Plasti-Dipping, it can be painted in any colour you want. It should still have a fair bit of flex after all is done, but if it's flexed too much, the paint may develop some hairline cracks.
<p>Hmmm, nice job! I think I'll go with cement adhesive and white plastic dip from the go. Other than that, I think it'd be helpful to let others know eva foam can also be found at walmart same price more foam. </p>
<p>hey, for a more authentic Clone Helmet, grab some white tape and tape an inch above the bottom of the visor and diagonally tape it upwards. you may need to experiment with this until you get it just how you prefer.</p>
What bit did you use for the Dremel to make the cuts?
I used a thin grinding stone bit.
nicely done, this has been helpful for my captain rex costume <br>
Wonderful job!
The costume looks really great. Nice work! You mentioned the paint cracking if you flex/bend too much, and I was wondering if it'd be possible to get similar results by simply using a glossy white latex paint in place of the plasti-dip &amp; spray paint? You'd probably also have to do a few coats, but latex paint flexes &amp; stretches pretty well.
I've done painting on my clone trooper armor and have used the Krylon Fusion paint that flexes with the EPS(?) plastic I have used. <br> <br>It flexes just enough and doesn't crack (unless you want it to for weathering) under normal use.
I considered using a latex-based paint, but I couldn't find any. It probably would flex better than the spray paint, but I haven't tried it yet. Maybe next time!
Top job, and using those rubber floor tiles has given me a few ideas; have a number of them laying about the house.<br>You might be interested in the suit I made from cardboard recently for my ten year old. <br>https://www.instructables.com/id/How-to-Make-a-Childs-Clone-Trooper-Costume-from-C/<br>One of the advantages of foam would definitely be comfort for the wearer and ease of mobility.<br>Love your work.
Thanks mate! And I have to say, your armor is pretty tob job as well. When you said you made the helmet out of cardboard, I didn't believe it until I saw the in-progress pictures!

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