Captain Rex Costume
Lead the 501st Legion with this authentic Captain Rex armor guide.
Captain Rex (CT-7567) is one of the most iconic Clone Troopers in the Star Wars franchise, famous for his leadership in the Clone Wars and his loyalty to Anakin Skywalker. His distinctive look features customized Phase II clone armor with blue 501st Legion markings, weld lines, and a fabric kama skirt. This guide helps you recreate his battle-worn commander aesthetic using ready-made armor or DIY methods.
- Difficulty
- Advanced
- Time
- ~120 min
- Budget
- $150–600
Try it on
See yourself as Captain Rex
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What you need for a Captain Rex costume
Short on time? Buy it ready-made
Spirit Halloween sells the complete Captain Rex costume — one box instead of 6 pieces.
Captain Rex Phase II Helmet
A white clone trooper helmet featuring blue 501st markings, black weld line details, a rangefinder on the right side, and a black T-shaped visor.
DIY: Paint blue markings and black weld lines onto a standard white Phase II clone trooper helmet using acrylic paint.
Clone Trooper Armor Set
White chest, arm, and leg armor plates with blue painted accents and tally marks on the arms and helmet.
DIY: Craft armor plates using white EVA foam sheets, heat-shaping them to fit and painting blue details.
Black Bodysuit
A snug, two-piece or one-piece black compression suit worn underneath the armor plates.
DIY: Use a plain black long-sleeve athletic shirt and matching black leggings.
Blue and Gray Pauldron
A fabric or foam shoulder piece worn over the right shoulder, featuring a blue shoulder guard and a small storage pouch.
DIY: Cut the pauldron shape from black and blue EVA foam or heavy vinyl, adding a small fabric pouch to the front strap.
Grey and Blue Kama Skirt
A split waist-skirt made of heavy grey fabric with blue trim, worn around the hips.
DIY: Sew a half-skirt from grey canvas or denim, trim it with blue fabric tape, and attach it to a black utility belt.
Dual DC-17 Blaster Pistols
Two grey and black hand blasters, Rex's signature dual-wielded weapons.
DIY: Modify toy blasters with black and silver spray paint to give them a metallic, weathered look.
Rather not assemble it? See ready-made Captain Rex costumes at Spirit Halloween ↗
How to put it together
- 1
Put on the black compression bodysuit as your base layer.
- 2
Secure the thigh, shin, and boot armor plates over your lower legs.
- 3
Fasten the chest, back, and shoulder armor plates over your torso.
- 4
Attach the blue and grey pauldron over your right shoulder, securing the chest strap.
- 5
Wrap the grey and blue kama skirt around your waist and secure the utility belt over it, ensuring the dual holsters sit at your hips.
- 6
Slide on the forearm and hand armor plates, then put on the black gloves.
- 7
Place the Captain Rex helmet on, lower the rangefinder if desired, and holster your dual DC-17 blasters.
Makeup & hair
If removing the helmet, style your hair in a blonde buzz cut or wear a short blonde wig, and add a small band-aid or scar over your right eyebrow to match Rex's unmasked look.
Captain Rex for couples, groups, kids & more
- couples
- Pair with Ahsoka Tano or Anakin Skywalker for a classic Clone Wars duo.
- group
- Gather friends to dress as other members of the 501st Legion, like Commander Cody or Fives.
- kids
- Use a pre-made licensed Captain Rex jumpsuit with a lightweight plastic mask for comfort.
- Plus size
- Use flexible EVA foam for the armor plates to easily customize the fit to your measurements.
Tips
- Add weathering to the armor using watered-down black and brown acrylic paint wiped away with a paper towel to create a battle-worn look.
- Ensure your armor joints are secured with heavy-duty hook-and-loop tape (Velcro) to prevent pieces from shifting while walking.
- Wear comfortable black athletic shoes under your boot armor, as you will be standing and walking a lot.
Captain Rex costume FAQ
- What is the difference between Phase I and Phase II Captain Rex armor?
- Phase I features a finned helmet and clean white armor with blue stripes. Phase II (his most famous look) features a customized helmet with a T-visor, welded seam lines, tally marks, and a shoulder pauldron.
- How do I make the kama skirt for Captain Rex?
- You can cut grey canvas or heavy cotton fabric into two rectangular panels, trim the edges with blue bias tape, and sew or velcro them onto a black tactical belt.
- What weapons does Captain Rex use?
- Captain Rex signature weapons are dual DC-17 blaster pistols, which he carries in holsters on his kama skirt.
Did you know? Captain Rex's Phase II helmet is a custom hybrid that he welded together himself, combining the breath filter of the Phase I helmet with the visor of the Phase II design.