Kids First Order Stormtrooper - Battle Buddy

BobbyFromBUF

BobbyFromBUF

Well-Known Member
Hi all,

It's been a while, but I'm back at it. I saw the youtube video of the 8 year old boy and his dad who built the First Order TK from the 48" Battle Buddy Toy. After much deliberation, I've decided to build one for my niece. The idea is to finish this build for her 6th Birthday in March, have her wear it for a few years, and then hand it down to her brother.

Having recently completed my own ANH Stunt TK, and being approved for the 501st Legion myself, I feel like this project is within my abilities.

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I have only just begun work on this mini TK, but as usual, the RPF will be my outlet to share photos and progress. :)

First of all, LOL at this seller on Amazon.

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I originally bought the Battle Buddy for $99. After receiving the item I discovered that it had quite a bit of wear and tear. So, I complained through Amazon, and received a partial refund of $35. Making my up-front cost $65.

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I also purchased a kids 2 piece Disney First Order Stormtrooper Costume helmet.

I have more photos of this item, and I'll get a bit more in-depth with the build details later, but it turned out something like this....

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I actually did carve out the tube vents on ether side after taking these photos, but I'll add those later...

Alright, that's it for now. More details coming soon.
 
Have Fun! I did one of these for my son and he has trooped in it for over a year and is now almost outgrown the suit. If you need any tips feel free to ask!
I would recommend that you use three layers of mesh for the eyes instead of plastic lenses. They tend to fog up very fast with little kids and the additional ventilation helps them troop longer.
Also, a rotozip tool for or bit for your dremel will go a long ways to cleaning out the inside of all the parts.
 
Okay. I promised more details on how I altered the helmet. Here goes...

I started off with a cheesy 2 piece Rubies costume helmet.

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I hated the way the mesh looked. So, I ripped it out. However, I took it out pretty carefully and saved it. This way I'd be able to trace the shape for the replacement lens.

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The replacement lens is just from a cheap face shield from Harbor Frieght Tools. I think it was $3.

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I ordered a roll of reflective film. It was like $12, but it's 50' long, and I'll have it for some other projects later.

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I lined up the front and back parts of the helmet as best as possible to minimize the poor overlap from the original velcro.

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The two halves are glued together with a combination of E6000, CA+ glue, and hot glue. I used some small plastic scraps I had laying around to bridge the two halves.

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After some deliberation, I decided that the vents needed to be hollowed out. So I did that and added some screen mesh...

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I took the bucket over to my sister's house, and convinced my niece that I got a new helmet for myself. I told her to try it on anyways... she went for it.

It's an excellent fit!

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Last edited:
Psicorp7 said:
Have Fun! I did one of these for my son and he has trooped in it for over a year and is now almost outgrown the suit. If you need any tips feel free to ask!
I would recommend that you use three layers of mesh for the eyes instead of plastic lenses. They tend to fog up very fast with little kids and the additional ventilation helps them troop longer.
Also, a rotozip tool for or bit for your dremel will go a long ways to cleaning out the inside of all the parts.
Click to expand...
I actually already ordered a fan. I'm going to do a USB rechargeable power bank set up to a 50mm squirrel cage fan - just like my bucket :)

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Oops, this is a better photo...

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As for the lenses. I realize that according to the 501st Legion CRL - the lenses should be grey. However, I thought the reflective mirror lenses were a bit more intimidating. And, since she's a girl, I'm sure she'll be faced with the typical "Star Wars is for boys" line. I figure that the cooler, tougher, more intimidating I can make the costume, the less the other kids will mess with her.
 
Last edited:
Yea nice work....watched someone elses attempt but I liked yours better.....less pieces....the straps and buckles....nice....making a Captain Phasma for my Grand Daugther for the summer Con season after tax time....your build will help a lot.....
 
Okay. Here's my original video for the chestplate, backplate, and shoulder bells.

After I made this video I found that I didn't like the velcro. It wasn't really strong enough to secure all that weight/tension. So, I ended up gluing the entire shoulder bridge and shoulder bell attachment buckle directly to the backplate permanently. I also added an additional male buckle to the front that now connects inside the chesplate.

https://youtu.be/WVwclNpFygs
 
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