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My vacuum forming rig was the end result of a variety of shortcuts:Īll it really is is a couple of hotplates wired together with a foil-wrapped box for an oven. In this shot you can see me making negative molds of two of the calf halves: Here's a later shot of the sculpt in progress: If you're really interested in geeking out about it, check out starwarshelmets. In the years since I've learned more than I care to admit about the various versions of this helmet that have been made. As stormtrooper helmets go, it's fairly low-grade. This particular helmet was a discontinued "Classic Action" helmet from Don Post. To save myself time, I cheated and bought a helmet in advance. I then painted it black, mounted it on a platform with casters for portability, and set about sculpting the armor on top of it using oil-based clay from. Starting in May and following their instructions, I enlisted the help of an unwitting friend and she helped me make a fiberglass lifecast of my entire body from the neck down. I'd explain all of the details that went into the process of making these parts, but there's no way I could do it better than they did. The best resource I found in all of my research was, a website that lists all sorts of how-to articles for making replicas of Star Wars costumes. This notion launched me on a months-long creative fiasco that would consume most of my nights and weekends for several months.
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Second, the cheapest one I found (with no helmet, boots, gloves, or undersuit) cost over $800!īy my reasoning, if these folks could figure out how to make stormtrooper armor, there was no reason I couldn't do it too. First, they were all designed to fit someone around six feet tall (I'm five foot seven, clearly a little short for a stormtrooper). A quick perusal of eBay revealed that there were a variety of fan made suits available, but there were two main problems.
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That year I'd seen the Kevin Rubio short film TROOPS for the first time and decided that I needed my own set of stormtrooper armor. History conspired against me though and it wasn't until 2002 that I finally got a chance to put anything together. I had time and money to spend and I was looking forward to going all out for my first Halloween in years. If you'd like to see how I arrived at this point, there's more after the jump.Īfter being stationed in Japan for two years with the Navy I was scheduled to be transferred stateside again in late 2001. While I had other, earlier projects that were very involved, I'd have to say that this is the one that really set the hook for me.
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I've had a few people ask me what got me started in making all of my over-the-top movie and video game costumes.