Exerpt (Click on picture for full article)
Back in August 2002 I started on a project; to create my own Star Wars Imperial Stormtrooper costume from scratch. Now, nearly three years later, and countless hours research, trial and error reverse-engineering and hard work, I finally have reached a point where I have a complete set of armor molds done. I’m still working on the helmet molds, but for now the body armor is done.
So, what does it take to make a stormtrooper costume? Well, the process is a complex one but not beyond what a fan can do in his spare time, and a few square feet in the garage. The first step is the vacuum forming machine. I must have made 4 different machines before I got one large enough to pull this project. The second step is the mold making. Different techniques have been used by other fans to make their trooper armor, but for me, I took advice from a fellow RPF board memeber, Phil G. aka Blaxmyth, and used MDF and Bondo to make the molds. The final step is to pull the plastic, trim out the parts, fit, paint and weather.