The replica suit of stormtrooper armor I built is a fan-produced kit. It's made of vaccum-formed ABS plastic, and is commonly referred to as the Armor F/X suit (altho' Lucas put Armor F/X out of business long ago). Assembling it was a very involved process, full of potential pitfalls. I did a ton of research on the project before I started - hours and hours of web-surfing looking for the most useful tips and emailing people for advice. My aim here is to share some of the best information I found, and methods I used along the way, hopefully to make it easier for other people to put together their own costume.