I know this is an old thread, but what a great tutorial! Thank you so much!!
I had started to make a Stormtrooper doll prototype a while back and also thought to use craft foam for the armor, but for some reason didn't make the connection when my 4 year old son asked to be a Stormtrooper this year for Halloween!
You saved Halloween!! Thanks again!
I think there would be a market for well designed/crafted kids sized SW costumes, honestly. I'm thinking about working on a kids Tusken Raider mask kit for next year!
Great armor to troopmaster also!!
-K