My first actual attempt at costuming was a great feeling to be able to put my long hidden creative side in the open. I also wanted a full set of Clonetrooper armor and unique. Well at the time the Galactic Marine was unique, only being seen during Episode III for 30 seconds. Scouring the internet was fun...not! The armor pieces back some five or six years was scarce and had to be by hand from screen shots, action figure and statute. The helmet was purchased from a reputable vendor who was doing his first run. Now the helmet was a raw cast meaning it did have the lenses, cloth or even paint. I hand made about 60% of this armor myself and was dissatisfied for some on the various parts. This armor - in order to join the 501st costuming legion - was judged with a fine tooth comb. To this day I still have unfinished parts such as the back pack. Most of the armor was made through thermal molding and vacuum forming. The forming technique mention is heating plastic and overlaying it on a mold and push the plastic down while a vacuum is on which sucked the plastic down like a seal-a-meal packing system. most of the cloth goods except the gloves and undershirt was handmade.
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Galactic Marine
Revenge of the Sith