Kid's Stormtrooper Costume

This is my cheap attempt at stormtrooper costumes for my 4 and 6 year olds. It's made to be lightweight and flexible for comfort but still hold true to the movie armor and look cooler than the store-bought stuff out there. Because of the materials used, these costumes won't hold up to rough play or prolonged wear. Actually, they got pretty beat up after simply trick or treating. Within the steps I'll tell you how I did certain things and what I would do differently. My son's costume was my first attempt and spent about 18 hours on it, not including drying time for paint and glue. My daughter's costume took less time because I based it on my son's templates just smaller and I gave it a little less detail (and I was less careful with cutting and glueing). Anyway, hope you find the instructions helpful. The result was a ton of fun and the kids got a lot of attention. Cheers

Step 1 Materials

 I used foam sheets from Michaels. The larger costume for my 6 year old to 9 of the 12" x 18" sheets. He's 50" tall and weighs 50 lbs. I used a combination of a glue called Quick Grip (which held very well and stayed flexible but is messy and needs to dry overnight) and hot glue (for adding some of the detail work.) By the time I got to my daughter's costume I got a little impatient and used the hot glue for most of the glueing. I worked ok as long as you are quick with getting the pieces together quickly. But it does deform the foam a little and it is not flexible. You're also gonna need a couple of packages of white velcro strips (18" in length). And you'll need a length of 1" wide black elastic for the upper arm pieces - both for a strap around the arm and to attach them to the shoulder straps. I also used some to hold the thigh pieces up - one end hot glued to the thigh piece and the other has a velcro piece that attaches behind the belt.

Comments

[gigibugs]

THANK YOU for this- I followed these instructions fairly closely and made my 3- year old an awesome costume this year. Looks great! I did have to modify a few things simply because he is three. I made the helmet and he won't wear it (bummer) so I ripped it back apart and he's better with just the mask.
Thanks again! Will add images soon!

[cpalmer3]

I had the same idea! I wanted to use craft foam to make the armor for my boyfriend's stormtrooper costume, but I didn't know how well it would work. Now I have a guide to help me along! Thanks for sharing!

[MagicScarf]

would you be able to tell me what website you bought an astronaut helmet from? so this isn't a motorcycle helmet but a real helmet an astronaut would use in space? i was really surprised to hear you bought it for under 10 dollars....i thought something like that would be worth a fortune...

i don't have much money this year for a costume and really want to try making this stormtrooper costume for myself. i'm an adult but i think by following your instructions i'll be able to figure out something that will have an impressive result.
please let me know where you got the astronaut helmet? : )
the costumes you made your children are fantastic. :)

[grey_starr]

http://www.birthdayinabox.com/party-supplies/productdetail.asp?prodsku=11867&SSAID=91948

[TheInventor1997]

probably a costume helmet, looks fake, no seals fake, ya fake

[Extinct]

Haha I thought that about the astronaut helmet too when I read it. But I think she bought a Halloween astronaut helmet. (not appropriate for outer-space use)

[halo 3]

I am such a stormtrooper fan!

[CluainnFhada]

I thought that this'd take ages and be super expensive... you certainly proved me wrong.

[mcneilre]

Did you say you made that out of fun foam!!??!! That's beyond amazing!!!

[kenbob]

Brilliant!

[brodycyn]

Im trying to make this costume now. Love what you have done. But you didn't lable the different patterns & I am having difficulty figuring out some of the pieces. (where do the go on the body) I need some help!

[Screamo]

Pink ruinds it 5/5!

[MagicScarf]

yeah i found the helmet, but it's only in kids size, it's a costume prop....nothing came close in adult size though.

[TheInventor1997]

not too acurate, i mean, where's the canister, the belt, the place where you put a thermal detonator

[jgderuvo]

Aside from the pictures above (which work really well), did you by chance create templates? Can you post them? Great job.

[pofoke]

How long did it take you from gathering all materials to completion? I'm going to attempt to put one together for my son for halloween this year, only as one of the clone troopers.

[dearfion]

haha ..pretty cool ah..

[NaesDraw]

Yeah, it seems like you could make any armor like this, I'll have to remember this. Props dude!

[NaesDraw]

Other idea. I was messing around with foam, and was thinking of a way to make it holdup better. I don't know how effort-wise effective it would be, but a test piece of foam laminated with clear packing tape on both sides became tougher and shinier.

[hirerob]

I was thinking that too. A medieval knight or a pretty sweet Ironman.

[sirtom68]

Thats just way 2 kool....i wannabe a storm trooper!!!

[blindskate]

cool!

[Speedmite]

"Arnt you  little short to be a stormtrooper?" or somthing like that. =P

Great job!

[jenniferdowns]

What an amazing Dad to do this for his kiddos.  They'll remember these always!! (especially if there is a scrapbook page dedicated to it!)

[hirerob]

 Thanks Jennifer! I'll tell Valerie to get right on that.

[sedica]

holy crap! that is so clever and such a cool kids costume! 

[Spycrab]

sweet!!
may actually have to try this for next halloween, or the next con i go to >.>
may the force be with you

[Karroo Oakey]

Great costume, Great effort, Superb result  - Great Dad!

[chwbcc]

Very NICE!  I love the simplicity.  Very clean and of course everything looks great in PINK!

[phalanx447]

That is something to be proud of! Very nice work. And your kids will remember that for a long time to come, as well. You are definitely a cool dad. :)

[Casabamelon]

"Aren't you a little short to be a Stormtrooper?"

[soapbox derby car]

you just made my day!

[ljdarten]

hehe

[canida]

:D

[Very Interesting]

How cute is the pink? Barbie, eat your heart out.

[hirerob]

 Thanks to everybody for the nice comments!

[KryptoCleric]

The Pink Heels rock!

[sammcj]

 These are great!  Nice work!  Your kids must have been thrilled.  Obviously the costumes are far and above what you would buy at the store but better yet theres that added dimension of having a parent spend the time and effort to make their halloween so memorable.

[hugedom]

They look awesome and the idea could be transferred to the clone troopers and many others.   Very sweet.

[teejayhanton]

Fantastic work! So the bulk of the armor just literally wraps around and velcros on? Excellent. I'm going to apply this to Clone Trooper armor, since my son loves the clones.