How to Make a Child's Clone Trooper Costume from Cardboard

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Picture of How to Make a Child's Clone Trooper Costume from Cardboard
October 29th 2011 Jady's 10th birthday 026.jpg
October 29th 2011 Jady's 10th birthday 024.jpg
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.
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Step 1: The Breastplate

Picture of 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.
seamster3 years ago
By far my favorite costume on here in a long time.

I recently introduced my four boys to Star Wars... and this is something we'd considered, but it seemed too daunting. It turned out really well, and doesn't have that "ahh-shucks-it's-homemade" look. Killer work.

Best of luck in the contest!
parrster (author)  seamster3 years ago
Thx Seamster. Star Wars is a great movie(s) in regard its ongoing enjoyment factor. Having made a Boba Fett helmet, I felt ready to attempt something bigger; and yes, I was aiming to avoid that home made look. Thanks for appreciating.
TheDentedChestplate made it!17 days ago
I surely recommend to detail the back,anyway it does,i mean, it REALLY DOES LOOK GREAT if i were Lucas,i would hire you for my staff! Keep up the Good Work!
parrster (author)  TheDentedChestplate17 days ago
Thanks Champ, appreciate the feedback
Colonel Hogan4 months ago
Nice job tho
Colonel Hogan4 months ago
Please make a ible for the shoes, i saw sneakers
rodney.lim7 months ago

This is such a cool costume! Do you have the digital templates? I would like to try make one for my 5 year old! He loves Star Wars!

parrster (author)  rodney.lim7 months ago
Hi Rodney. Unfortunately I don't have any templates. This was a design and build project, and as such no templates were used. I did attempt to work out some crude templates, but it all got too hard. Sorry to disappoint.
pjadenalex1 year ago
What did you use for the black part behind the eye holes so he can see out of the helmet?? btw Great costume!!!!
kiddooddle2 years ago
is there a youtube video for this
parrster (author)  kiddooddle2 years ago
Sorry kiddooddle, but no, there is no youtube video. Would have been a good idea though.
vtheawesome3 years ago
could you please leave the picture of the templates here, or even a link?
parrster (author)  vtheawesome3 years ago
I'm presently working on getting the templates into a digital format. I'll let you know when uploaded.
Honus3 years ago
Wow- that looks fantastic and it seems like you guys had a great time building it!
parrster (author)  Honus3 years ago
Thanks Honus. We did indeed have a great time, so much so that now my youngest daughter wants one (back to the drawing board :)
Honus parrster3 years ago
All three of my boys (ages 3, 5 and 7) really got into Halloween this year so I'm sure I'll be working on some great stuff for them next year. Three Clone Troopers would be cool. :)
parrster (author)  Honus3 years ago
I just realised your the dude behind the Boba Fett cardboard helmet. Kudos to you sir! I used your insructable as a reference when it came to making the helmet for the Clone Trooper; many thanks.
I've just read the Featured Author writeup about you... even more Kudos to you. You seem quite the remarkable individual. I look forward to seeing the latest CNC machine. all the best.
Honus parrster3 years ago
That's very kind of you to say- I guess I'm always trying to figure out how to make cool costumes more accessible. It's really cool that you were able to take what I did to a whole new level- the Trooper costume really looks fantastic and that's not an easy helmet to make! Stay tuned- I'll have my latest costume creation up soon. The CNC is coming along nicely as well. :)
r-philp3 years ago
Where did you get the thick cardboard?
parrster (author)  r-philp3 years ago
It was given to me by a friend, it was what remained of a pallet of damaged cardboard no longer suitable for retail.
Lucky have a dad of your talent.
parrster (author)  The Papier Boy3 years ago
Thx PB. 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!
Fypsigon3 years ago
This is just......WOW!!!!!!
parrster (author)  Fypsigon3 years ago
Thx Fypsigon, I am very pleased with the final result. Next I'm planning to build a vaccum-form and see if I can duplicate using thermoplastic.
omnibot3 years ago
Holy sci-fi! That is awesome! Peoples heads must turn a bit when a halfsized clonetrooper runs by.
parrster (author)  omnibot3 years ago
Thx Omnibot. Yes, my son took it out trick or treating last night and had many requests to pose for photos; not something you see every day. Thanks for commenting