***********Work in progress. I have yet to finish the chest armor and all left arm/leg pieces.*************
This is my first Instructable, and my entry into the Instructables 2007 Halloween contest. Baseline cost is around 150 bucks for a full suit. Difficulty is moderate.
I've always wanted to make a stormtrooper's costume. But when I saw a homemade suit of Spartan armor straight out of a Halo deathmatch, I knew I just had to make my own. So I hit up google and found the amazing forums at 405th.com . This is a guide to folding paper pieces(pepakura), resining, fiberglassing, and finishing them for paint, along with simple suggestions to complete them. I won't be covering the details for every piece of a suit, I will use simple pieces like the bicep as an example.
Step 1: Tools, Supplies and Materials.
The one key part of this suit is Fiberglass and resin. lots of it. So far, I've used 5 quarts of resin, and 3 packs of fiberglass. That was enough to resin-coat all the pieces, and fiberglass the right arm, helmet, chest, crotch, and right leg. So I'm going to guesstimate on total quantity here(marked with * for unsure-ity). Note that this list includes only what you need for making the pieces. I'll get to other detail and accent pieces like the gold visor and such later in this instructable.
Dremel with cutting disc and sanding bit
Hot-glue gun with plenty of sticks
9 quarts of Bondo resin*(two gallons and a quart=70 bucks)
5 packs of Bondo fiberglass cloth(25 dollars)
Bondo Body Filler(not pictured)
about 200 sheets of 110 lb. press cardstock(not pictured)
"Medium Grit" Sandpaper
Primer for sanding aid(not pictured)
Some type of rubber gloves(disposables)
Container for mixed resin(i use the lid from the quart can, and line it with aluminum foil so I can use it again)
Measuring paraphernalia(teaspoons, tablespoons, etc. make sure you'll never need em for food again)
Facemask or respirator for working with resin/fiberglass/sanding
Tape and super glue