Download: How to make Stormtrooper Armor - Vacuum-Forming Tutorial with the NakedTrooper

By James Hannon


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During trooping for the 501st Legion, I get asked all the time, "How do you make your costume?" And its hard to explain how to make the armor portion of the costume which is called vacuum-forming. So my fellow 501st buddy Lance (aka the Naked Trooper) and I decided to show just what goes into making the plastic armor that makes up costumes like stormtroopers, biker scouts, and TIE pilots.

This is the inexpensive version. There are plenty of more sophisticated methods out there, but this is Lance's set up, so we went with that... I like it since it shows that you don't need to spend thousands of dollars to do this... Just some talent and ingenuity...