TrooperArmor.com
How to build a Stormtrooper Costume

How would you like to own your own set of Star Wars Stormtrooper Armor? If you do and have lots of free time on your hands, this website will show you how. It's really not that difficult and with the help of this website you should be able to completely build your set of armor in about 160 Hours and for under $1000.00. The process described here consists of creating Molds of the armor pieces, Vacuum Forming Styrene over those Molds, and Assembling the Armor. Follow the links below to learn more about these processes.

Here is a diagram illustrating the production process. A big decision you have to make before you undertake this project is to decide what materials you want to make your molds out of. I made my costume using a combination of Wood molds and Clay / Plaster molds. I had originally planned on making all of my molds out of claym but I found it much too difficult and time consuming. I actually have gone back and recreated most of my molds out of wood.