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.
The model is my ten year old son.
Step 1: The Breastplate
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.
2mm wire is a useful way to capture the unique contours of the wearer
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.