As I posted at the MEPD, here are the interesting things I found.
"George announced that he was going to take some stormtroopers on location, and he wanted them to be in 'combat order.' I said 'Oh yes, George, what's combat order for stormtroopers?' and he said, 'Lots of stuff on the back.' So I went into this Boy Scout shop in London and bought one of these metal backpack racks; then we took plastic seed boxes, stuck two of those together, and put four of those on the rack. Then we put a plastic drainpipe on top, with a laboratory pipe on the side, and everything was sprayed black. George asked, 'Can we have something that shows their rank?' So we took a motocyclist chest protector and put one of them on their shoulders. George said, 'That's great.' We painted one orange and one black and that was it."
One item that stood out [of the wardrobe budget] was te cost associated with the stormtroopers, tho ran up a tab of ($93,000) [The total wardrobe budget for Star Wars was $220,000, so the stormtroopers were almost hald the budget.] - and whose final outfits were still not ready a week before location shooting was to begin . "Stormtroopers were the nightmare costume," Mollo explains. "We got a model in of a suitable size, did a plaster body cast, and Liz Moore modeled the armor onto this figure. Then everybody used to go in and say, "Arm off here, arm off there," and George changed all the kneecaps. This went on for several weeks. Finall that was all taken away and produced in vacuum-form plastic - but the next question was: How does it all go together? And I think we had something like four days before shooting , but we just played around until we managed to string it all together in such a way that you could get in on and off the bloke in about five minutes.
This is GREAT info for us stormtrooper fans. I have long suspected and championed the boy scout packs and now it is confirmed. Now if we can just find those seed trays...