How the process works
When you click to buy you will be commission a set of Stormtrooper armour built to your requirements. We will then send you, via email the size data we require along with instructions about how to correctly take the measurements. We ask you to follow the instructions closely, as these sizes ensure we can guarantee the suit will fit you correctly. The suits are not made to a standard size and are not made with any hook & loop and popper closures, they are built to the same specifications as the screen used suits, to your requirements. All our replica props are made from start to finish in our Prop Studio, near Manchester, England.
When assembled we ship the suit directly to you, the whole process typically takes six to eight weeks. During the build we will update you a key points of the commission and can share images of the build as it is happening to keep you informed as to the current status of your Stormtrooper.
Replica Stunt Helmet Details
Our stunt helmet is created from mouldings taken directly from our original helmet. The original helmet is owned by RS Prop Masters and is retained in our secure archive. This is important as it allowed us to take the time required to create the moulds of the helmet, and armour over a extended period of time, without and need to rush or ‘make do’. Every detail was captured and retained, nothing was added and more importantly nothing was removed, to create as near perfect replica as possible. This was the intention of RS from day one, we wanted to bring a full screen accurate suit to the prop community, we had the opportunity to be the only lineage “A New Hope” & “Empire” suit available, and we still are!
This desire for a “purist” suit means it includes surface texturing to the front of the back and cap, the large blemish that screams ‘RS’only and various small details around the face plate, including the ‘oval’ trap detailing and ‘crushed’ tube detail.
The ‘bucks’ used to create this replica helmet and first generation and as such suffer from no shrinkage, meaning the replicas are the correct movie size. The helmets are made from the same gauge of plastic, to ensure the details are reproduced correctly, the thickness of the plastic we use does not alter the detailing. This was the most important issue after retaining the details from the originals during the mould making process.
The stunt helmet comprises of a faceplate, back and cap and two separate ears. The helmet is then assembled by hand, firstly trimmed to size, then riveted together and the ear caps secured with screws. The internal components are then added, yellow foam star, green lighting film for the eye lens and an elastic chin strap, with replica vintage ’S’ spring snaps. The helmet is completed with accurate rubber trims and castings of our original Hovi-mix ‘Mic Tip’ greeblies, before being finished into the desired style; “A New Hope Stunt, Sandtrooper or The Empire Strikes Back.
Please note the finished helmets are full prop replicas, with the hand painted detailing and textured surface adding to the complete look overall look of the helmets, but may not be the finish expected, these are not mass produced collectables, they are hand made props, in the exact same style and spirit of the helmets used on set. This, we believe is the reason to choose RS Prop Masters.
Replica Armour Set with screen used assembly method
RS Armour is, like our Stunt Helmet, created from a mouldings taken directly from our original armour. The original armour is owned by RS Prop Masters and is retained in our secure archive. This allowed us to take the time required to create the moulds of the armour over a period of time without and need to rush or ‘make do’. Every detail was captured and retained, nothing was added and more importantly nothing was removed, to create as near perfect replica as possible. This was the intention of RS from day one, wanted to bring a fully screen accurate suit to the prop community. We had the opportunity to be the only lineage “A New Hope” & “Empire” suit available, and we still are.
This desire for a “purist” suit means it includes various small details around the suit which add to the overall look when viewed in its entirety. The ‘bucks’ used to create this replica and first generation and as such suffer from no shrinkage, meaning the replicas are the correct movie size.
The armour set comprises of forty individual vacuum formed components and sixteen joining strips. These include:
Fifteen torso parts, two shoulder bells (straight and sweeping, not matching) chest, abdominal, butt, back and kidney/middle back sections. One pair of shoulder bridges (not Sandtrooper) and main belt front, two abdominal button details (not Sandtrooper) and three main belt rivet covers.
The limbs are made from eighteen formed parts, two for each of the following components, left and right bicep, forearms, thigh and shin, with knee ammo belt and knee sniper plate (diamond for Sandtrooper) and finished with the thermal detonator (Not Sandtrooper).
The armour is trimmed by hand with the correct return edge distance retained, these hold the eighteen metal fixing brackets for torso assembly. The torso is then ‘strung’ together with black elastics to form one complete body piece. The limbs are all two sections joined to form a “tapered tube section” using the joining/cover strips. All but the shin sections are joined front and back. The rear of the shin is closed using an elastics and hook system. The arm sections are joined with elastics and the thighs are held by a belt, again using elastics. Knee detailing belt is fixed with rivets and the sniper plate is attached without visible fixings (bonded) as per the original screen used suits.
The assembly method we use is as per our screen used suit and years of research into the correct assembly methods. Many suspected methods were confirmed from the assembly of our suit when the details were made public.
The armour is completed with a full replica belt. The belt is constructed from six layers of fabric, all of which have been identified from our original belt, This is finished with the main ammo belt front, riveted in place with rivet covers and four part drop boxes (not Sandtrooper) and full size replica thermal detonator (not Sandtrooper), the correct type of rainwater tubing with aluminium belt clips, again, exact replicas of the originals used
Our standard Imperial Stormtrooper Commission meets 501st Centurial level in most cases, limitations may apply to some body shapes and sizes.
The armour is made from the same gauge of plastic as the original suit to ensure the details are reproduced correctly. The thickness of the plastic can alter the detailing if too thick or thin. Getting this right was the most important issue after retaining the details from the originals during the mould making process. We offer the suit in two plastic options in this gauge. ABS (Acrylonitrile butadiene styrene) and PVC (Polyvinyl chloride). ABS is the material the original suits were made from. It will hold paint well and vacuum forms very well. It is strong and flexible at the gauge. It is a slightly off, or creamy white with a subtle gloss finish. PVC is brilliant white and high gloss finish to achieve a more idealised Stormtrooper. PVC is also UV Stable and will not ‘yellow’.
Replica E-11 Blaster – ANH style
Our replica blaster is cast directly from an original Sterling Machine gun, including the individual serial number of our gun. It is finished with a metal scope rail and castings of tank scope and “helsinger” counter box, with the correct ‘eagle logo’ present. The blaster also features accurate “T-Track” and cylinder greeblies.
Our blasters are pressure cast to eliminate unwanted air bubbles. Constructed from seven separately cast parts from our own a high quality PU resin blend with black pigmentation. The blaster is produced with an inner aluminium core to add strength, yet lower the finished weight of the prop, also allowing for the holes to be drilled out to create a more accurate look and for the correct fitment of the scope rail. The prop is then assembled and painted by hand to create a stunningly detailed blaster replica.
Replica E-11 Blaster – ESB style
Our replica blaster for The Empire Strikes Back style Stormtrooper is cast from a studio made ‘background’ blaster. This replica is another RS Exclusive and can only be supplied by RS Prop Masters.
Two Part “RS” undersuit, exclusively made for us. These suits are 95% cotton and 5% lycra to give a flat black colour with some stretch to ensure your suit does not sag. Finished with RS branding across the chest (placed to be hidden in armour) so you can be proud when de-kitting!
Supplied with black rubber chemical gloves with rubber latex hand guards painted white (ANH Style). These can be supplied in a natural latex finish painted white which will wear and chip, or pigmented style that will not chip. A set of plastic hand guards to compliment your armour are also included.
Supplied with black silk gloves for ESB style with plastic hand plates “stitched” to the gloves.
Neck seal made from black vinyl. Made to your size requirement, our neck seals are ribbed and seal at the rear with velcro. The bib can easily be trimmed by the individual for the best fir as required.
Leather E-11 Holster supplied fitted to the belt in the correct position and fixing method (ESB style is loose). This holster will safely hold the replica blaster to the correct dimensions.
Boots, black leather style riding boots, painted white, again in the style of the original screen used suits. Available in sizes up to UK12
To complete your Brian Muir Edition Stromtrooper is a display plaque, signed by Brian himself. Along with 3D Hologram authentication stickers and individually numbered Certificate of Authenticity.
We have a full compliment of replacement armour parts as required available to clients who own an RS suit. Parts deemed to be defective or in rare circumstances below our high quality standards are replaced free of charge. When considering a part as defective please remember this is a replica prop and not a mass produced collectable, asymmetrical helmets, with textured surfaces and armour with odd lumps and bumps are inherent with the authenticity of the prop.
We understand the needs of our clients and work hard to ensure 100% satisfaction. If you are commissioning a suit to join the 501st Legion we guarantee the suit will be to a standard that will obtain admittance/clearance. Remember, you are not buying a box of plastic, you are buying an Icon and we are here to support you now and in the future.
*Recommended for display only, we can not take any responsibility for injury caused when wearing any props supplied by RS Prop Masters as per our terms and conditions.
Fan made replica props, not affiliated with Lucasfilm Ltd in any way.