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
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Signing UpStep 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.








































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I'm looking forward to building this for my son this Halloween...
I second the request for templates if you still have them! Pretty Please.
Note to new/potentially new users: I thought the PDF which you can't download without a paid membership would contain the templates: It doesn't. I paid a full years subscription because for me the templates for this costume were worth $24. I'm not complaining, or accusing, just letting other's in my situation be aware.
Thanks again! Will add images soon!
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. :)
Great job!
may actually have to try this for next halloween, or the next con i go to >.>
may the force be with you
hehe