DIY Scout Trooper Armour: Build Your Own Accurate Set

Crafting screen-accurate Star Wars cosplay is achievable, and The 501st Legion, the premier costuming club, sets a high standard for replicating the armour seen in the films. The goal of this project is the creation of your very own scout trooper armour, a distinctive look that offers more mobility than its stormtrooper counterpart. Utilising techniques championed by talented prop makers like Harrison Krix, this guide provides clear instructions to build a set of armour worthy of patrolling Endor itself.

Crafting Your Own Imperial Ride: A Guide to DIY Scout Trooper Armour

So, you’re ready to embark on an epic journey to build your own Scout Trooper armour? Excellent! This guide will break down the process into manageable steps, ensuring you create a screen-accurate (or close to it!) set that will turn heads at any convention or gathering. We’ll cover everything from planning to painting, making sure you’re equipped with the knowledge to succeed.

First, let’s talk about the core components of your Scout Trooper armour. Think of it as assembling a complex puzzle, where each piece contributes to the overall awesome picture:

• Helmet: The iconic focal point!
• Chest and Back Armour: Protecting your vital organs (from blaster fire, of course!).
• Shoulder Bells: Adding that signature Imperial flair.
• Biceps and Forearm Armour: Covering your arms and completing the armored look.
• Hand Plates: Often overlooked, but crucial for a complete set.
• Abdomen and Kidney Armour: Providing lower torso protection.
• Thigh and Shin Armour: Protecting your legs from the knee down.
• Boots: Modified motorcycle or combat boots are the way to go!
• Pouches and Accessories: Bringing that ultimate Scout Trooper finishing touch.

Now, to create our armor we will need to go through this key steps:

1. Research and Planning: Before you even think about cutting plastic, research is your best friend. Gather reference images from movies, forums, and online build logs. Decide on the specific style of Scout Trooper you want to create as there are slight variations, such as the Return of the Jedi or The Mandalorian variations. Consider your budget and the available tools. Remember, building Scout Trooper armour is a marathon, not a sprint!

2. Choosing Your Materials: The most common materials for Scout Trooper armour are:

   • ABS Plastic: Durable, paintable, and relatively easy to work with. A popular choice.
   • PVC Plastic: More affordable than ABS, but can be more challenging to shape.
   • EVA Foam: Lightweight and easy to cut, but requires sealing and more robust painting techniques for durability.
   • 3D Printed Parts: This is becoming increasingly common, offering high accuracy and detail. It does require access to a 3D printer or a 3D printing service.

3. Acquiring or Creating Templates: Templates are your blueprints. You can find free templates online, purchase pre-made templates, or even draft your own. If you are buying a pre-made armour kit, they will come as standard. Remember to consider your body size and adjust the templates accordingly. Ill-fitting armour looks… well, it looks ill-fitting!

4. Cutting and Shaping: Here’s where the fun begins! Using your templates, carefully cut out the armour pieces from your chosen material. This requires patience and precision. For plastics, a jigsaw, bandsaw, or rotary tool can be used. For foam, a sharp craft knife is essential. Use heat-forming techniques (heat gun, oven) to shape the plastic pieces to the contours of your body.

5. Assembling the Armour: Bonding the various parts together.

   • Joining Armour Pieces: Use appropriate adhesives for your chosen material. ABS cement works wonders for ABS plastic. Contact cement is often used for EVA foam.
   • Strapping Systems: Securely attach the armour pieces to each other and your body. Elastic straps, Velcro, and snaps are your friends. Experiment to find a comfortable and secure fit.
   • Hardware: Rivets, screws, and bolts can add structural integrity and visual detail.

6. Filling and Sanding: Achieve a smooth surface with body filler (bondo) to fill any gaps or imperfections. Sand meticulously, starting with coarse sandpaper and gradually moving to finer grits. Remember, the smoother the surface, the better the paint job will look. This step will be un-necessary if the armour is 3D printed, or if it comes as pre-made kit.

7. Painting and Finishing: The most important step!

   Step	Description
   Priming	Apply several light coats of primer to create a uniform base for the paint.
   Base Coating	Spray the entire armour set with your base color. Scout Trooper armour is typically white with black details.
   Detailing	Carefully mask off areas and paint the black details. Use reference images to ensure accuracy.
   Weathering	Optional, but it adds realism. Use techniques like dry brushing, washes, and sponges to simulate wear and tear. Think blaster fire, mud!
   Clear Coating	Apply several coats of clear coat to protect the paint and give the armour a durable finish.

8. Adding the Details: Adding that finishing touch!

   • Pouches: Attach the required pouches to the belt and thighs. These can be purchased or made yourself.
   • Holster: A necessary accessory for your blaster pistol.
   • Neck Seal: The neck seal helps the Scout Trooper avoid wind burn and sun exposure.

Remember, this is a challenging but incredibly rewarding project. Don’t be afraid to experiment, learn from your mistakes, and most importantly, have fun! And remember, you can customize your armour to your preferences!

So, there you have it! Hopefully, you’re now armed with the knowledge and inspiration to tackle your own DIY scout trooper armour build. It might seem daunting at first, but breaking it down into manageable steps and leaning on the community for support will get you there. Just remember to be patient, have fun, and pretty soon you’ll be patrolling the forest moon of Endor (or, you know, your local convention) in a fantastic set of scout trooper armour you built yourself!