If you’ve been down the toy aisles lately, you’ve possibly seen the giant First Order stormtrooper toy for sale. It’s the size of a small child. Some people have realized the toy can be disassembled and turned into a costume. Replica Props Forum (RPF) user Psicorp7 did just that so his son could be in armor for The Force Awakens premiere. He had friends help remove the tons of screws on the costume with a long-handled Phillips head screwdriver, and then it was a matter of cutting out all the inside structure to make the armor wearable. He only had a little work to do on the helmet:
The good news is that the helmet fit my son! I gutted the innards and cut out the eyes. I replaced the eyes with a double layer of mesh to keep them from fogging up and allow better breathing. I kept the four screws and the mounts to be able to open and close the helmet.
I strapped the suit with black velcro to make it more adjustable and easy to remove. His mobility is limited but he has a couple more inches to grow into it over the next year.
See more photos and read more about the build at The RPF.