Have you ever wondered how the Stormtrooper armor from the Star Wars movies was made for the original film? Andrew Ainsworth, who is the creator of the original Stormtrooper helmets and also the armor has released a couple of videos which show how they were made.
Andrew still uses the same methods today as he did for the original movies to make Stormtrooper helmets and armor, have a look at the videos below.
You can find out more information over at Original Stormtrooper, and Andrew is even selling the authentic costumes, and they are only available in the UK and not the US as he was recently allowed to sell them in the UK only after a court case with Lucasfilm.
Source Wired / Geek Dad