What is the difference between Phase I and Phase II Clone Trooper armor?

Phase I armor features a helmet with a vertical fin and a T-shaped visor, while Phase II armor has a more rounded helmet design closely resembling classic Stormtrooper gear.

How do I make DIY Clone Trooper armor?

You can build lightweight, budget-friendly armor by printing paper templates, tracing them onto white EVA foam, cutting the shapes, and gluing them together with contact cement.

What should I wear under the armor?

A breathable, two-piece black compression suit or athletic gear is best to prevent chafing and keep you cool.

Clone Trooper

Clone Trooper Costume

Serve the Republic in iconic white and black armored trooper gear.

Clone Troopers are the elite soldiers of the Galactic Republic, first introduced in Star Wars: Episode II – Attack of the Clones. Fans choose this costume to pay tribute to legendary units like the 501st Legion or Commander Cody. The look consists of a form-fitting black undersuit layered with white segmented armor plates and a distinctive T-visor helmet.

Difficulty: Advanced
Time: ~45 min
Budget: $80–600

See yourself as Clone Trooper →What you need Buy the Clone Trooper costume

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What you need for a Clone Trooper costume

Short on time? Buy it ready-made

Spirit Halloween sells the complete Clone Trooper costume — one box instead of 5 pieces.

Shop Clone Trooper at Spirit ↗

Clone Trooper Helmet
A full-head Phase I (finned) or Phase II molded helmet with a dark T-shaped visor.
DIY: Modify a toy helmet with white spray paint and black acrylic paint for weathering.
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Black Undersuit
A two-piece compression set or a full-body spandex bodysuit in matte black.
DIY: Wear a black long-sleeve compression shirt and matching black athletic leggings.
Amazon
White Armor Plates
Segmented white chest, back, shoulder, arm, and leg guards made of molded plastic or dense foam.
DIY: Cut and shape white EVA foam sheets, heat-bend them to fit, and secure with elastic straps.
Amazon
Black Combat Boots
Sturdy, matte black tactical or combat boots worn under the shin guards.
DIY: Use plain black high-top sneakers or work boots.
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DC-15S Blaster Prop
The standard-issue black blaster rifle used by the Grand Army of the Republic.
DIY: Paint a toy space blaster matte black and add silver dry-brushed highlights for a metallic look.
Amazon

Rather not assemble it? See ready-made Clone Trooper costumes at Spirit Halloween ↗

How to put it together

1
Put on the black spandex bodysuit or compression layers as your base undersuit.
2
Secure the lower body armor pieces, starting with the shin guards and thigh plates over your legs.
3
Put on your black combat boots, ensuring the shin guards sit comfortably just above or slightly overlapping the boot tops.
4
Strap on the torso armor, securing the chest and back plates together at the shoulders and sides.
5
Attach the shoulder bells, bicep guards, and forearm plates using the integrated elastic straps.
6
Equip the utility belt around your waist, positioning it over the seam where the torso and thigh armor meet.
7
Put on the helmet, adjust the internal padding for a snug fit, and pick up your blaster prop.

Makeup & hair

Keep your hair flat or wear a wig cap so the helmet fits comfortably. No makeup is required, but you can apply dark grey smudge makeup around your eyes and cheeks for a battle-worn, unhelmeted clone look.

Clone Trooper for couples, groups, kids & more

couples: Pair up with another trooper in matching armor, or go as a Clone Trooper alongside a Jedi General like Obi-Wan Kenobi.
group: Assemble a squad of troopers with different colored shoulder pauldrons or painted armor stripes to represent the 501st Legion or 212th Attack Battalion.
kids: A lightweight printed fabric jumpsuit with a molded half-mask is perfect for young recruits.
Plus size: Use adjustable elastic straps on separate armor plates to customize the fit over a black base layer.
pet: A white dog coat styled with printed armor details and a soft fabric headpiece.

Tips

Install small adhesive helmet fans inside the dome to prevent the visor from fogging up during conventions.
Use a gray or brown paint wash on the white armor plates to create realistic battlefield dirt and scuffs.
Wear moisture-wicking undergarments beneath the black bodysuit to stay cool under the plastic or foam armor.
Practice walking and sitting in the full armor kit beforehand to adjust any tight straps that pinch.

Clone Trooper costume FAQ

What is the difference between Phase I and Phase II Clone Trooper armor?: Phase I armor features a helmet with a vertical fin and a T-shaped visor, while Phase II armor has a more rounded helmet design closely resembling classic Stormtrooper gear.
How do I make DIY Clone Trooper armor?: You can build lightweight, budget-friendly armor by printing paper templates, tracing them onto white EVA foam, cutting the shapes, and gluing them together with contact cement.
What should I wear under the armor?: A breathable, two-piece black compression suit or athletic gear is best to prevent chafing and keep you cool.

Did you know? The Clone Troopers in Star Wars: Episode II and III were entirely computer-generated; no physical suits of armor were actually built for the actors during filming.