This Halloween I couldn´t find a costume to do so I looked around my dad's stuff and came across his collection of Star Wars helmets. I thought that it would be a good idea to be someone from Star Wars but couldn't figure out who. Eventually, I found that my Dad also had a collection of Star Wars Nerf guns and decided that I knew what I wanted to be. I asked my dad and then we started on my Scout Trooper Halloween Costume.

Supplies

Materials

Sand Paper
Fabric
Spray Paint
PLA Filament (for 3D printer)
Super Glue
Super Glue Accelerator
Bondo Spot Putty
Spray Primer
Black Turtleneck
Black Sweatpants
Black Buttons
Black Shoelaces
Elastic Strapping
White Boots
White Belt

Tools

3D Printer
Sewing Machine
Computer
Hobbie Knife

Step 1: Getting Started

In order to build this costume I needed 3D files so that I could print out the armor. My dad found this website called do3d.com and it had all the parts we needed to complete this project.

Step 2: 3D Printing Scout Trooper Armor

First, we needed to scale the armor to fit me because I'm a little short for a stormtrooper. After measuring my height we determined that I was 4ft 12 and we would have to reduce the size of the armor to 82%. We did this in the 3d printer's slicing software.
The next step was the printing the armor. There were a total of 20 pieces of armor that I needed to print for this project and It took about 3 weeks of continuous printing. Make sure to check on your prints from time to time to ensure that no ewoks sabotage your print.

Step 3: Prepping Armor

When the printing is complete, I chose to use Bondo Spot Putty on my armor because it would make it smoother. I covered all the parts with a heavy layer of Bondo Spot Putty and let them dry overnight.
After the Bondo finishes drying you MUST sand. You want to sand the armor until it is smooth and shows no scratches or lumps. There is no do or do not with sanding, there is only do.
With sanding out of the way we move on to painting. I started by using a white primer to cover the dark red spot putty. Once the parts were premiered, I finished them with a coat of gloss white enamel spray paint. Remember, this is a scout trooper, not one of Sabine's projects.

Step 4: Non 3D Printed Parts

As I said above, My dad had both a helmet and a Nerf gun for my costume. Specifically, the helmet was a Hasbro Black Series Scout Trooper helmet, and the blaster was a Nerf Scout Trooper EC-17 blaster.
We also purchased a pair of motorcycle gloves (size small), white rain boots, and a white belt for the costume on Amazon.com and eBay.
We picked up a black turtleneck shirt and black sweatpants at Target.
The last part we needed was the Scout Troopers “Cumberbun” which we purchased fabric for to make this at Joann Fabric. We purchased two different white fabrics, one for the cumberbun and one for the Scout Trooper pouches. We found a pattern for this at Studiocreations.com after resizing it to my ewok-like stature, we spent a long day sewing it all together.

Step 5: Final Assembly

Once we had all these parts together we still needed a way to attach them to me. We added elastic strapping to the knees, elbows, upper arms, and shoulders. For the chest and back armor, we placed loops of black shoelaces in them to attach to my shirt. For attachment points on the shirt, we added large black buttons that the shoelaces would hook onto.
We then glued the belt boxes onto the belt.
After test fitting several thousand times, we glued in some small pieces of foam floormat to the inside of various armor pieces where it pinched.

Step 6: Trick or Treat

After completing the armor I put it on and went out with my friends to trick or treat. My friends and I went out all night searching for two droids and a little green dude but only found a bunch of candy. At least I can report that no Ewoks were roaming the streets.