Anyone here ever made a stormtrooper or clone before? I've seen a lot of options online, ranging from buying pricy vacuum formed panels, to 3d printed components to eva foam shit. I'd either be opting for a generic phase 1 clone or Captain Rex.

I have made 3d printed armor/helmets before and honestly, they are a pain in the ass. It took me a good week of sanding and smoothing every evening to make pic rel for a NCR ranger - and it still didn't come out too good. My printer isn't large enough to print a helmet in one go, and the seams are still visible under certain lighting. I feel that'd be really bade for the glossy white finish of clone armor for all the body panels.