So you want to learn how to make your own Star Wars Imperial Stormtrooper? Good for you! This project has an unknown cost factor in both materials and time. Its a hobby! Cost is not a factor. You will need some specific skills, and practice. Don't expect your trooper gear to be cheap! At least the first one won't be. If you decide to make several version, remember, that vac-forming is easy, the hard part is making the first one! The second armor set will be cheap. Thats economy of scale working for you. There are several ways to make the molds, I like wood working, so thats how I did it. You could easily make your molds form clay, and then make palster molds/copies of them. The "wood" material I use is MDF. That stands for mult-density fiberboard. The reason I use make the molds from a rigid material is to save me the step of making an original pattern, then making a mold of it, then making a plaster copy to be used as the mold.

The following skills are needed for this part of the project:

• wood working skills, not limited to cutting sand and shaping.
• Art skills to include drawing and sculpture and pattern making
• Engineering skills to include machine construction and reverse engineering existing vacuum form machines
• patience and lots of time.
• A good workshop with the following equipment: Bandsaw, hand planer, files rasps, and sanders. A modest work area large enough for a vac-machine thats approx. 30" x 60".

Still interested?Then you will need the following materials to make your molds:

• 4'x8' MDF 1 inch thick. Don't get the laminated kind. I'd say you need at least 2 sheet for the molds, and one sheet for the vacuform machine.
• Carpenders wood glue. [get the large 1 QT size jug, not the gallon!]
• Bondo brand auto-body polyester resin. get this in the Gallon tin size.
• Bondo Spot and glazing putty
• Dupli-color Spot filler primer [lots of cans!]
• Dust masks, and eye protection.
• Tack cloth

Click here to view the MDF mold shaping video

Click here to view the vacuum forming video

Click here to view the RTV silicone mold making video

Click here to view the resin casting video