Store-bought costumes are always a bit... lacking, so when TJ Maggio came across Jakk Pacific’s 48 inch First Order Stormtrooper, and that it was the same height as his son, he saw the potential for a really spectacular halloween costume.
The $99 toy is enormous, and with a little work, it can be made into a fully functional Stormtrooper costume for a kid that’s around the 48 inch mark.
Watching the video, it looks like it’s a pretty simple process: cut off the arms and the legs. The toy itself is made from injection-molded plastic and is hollow, so all that really needs to be done is to remove the extra plastic between each armored part and on the inside.
To attach each part so that it didn’t fall off, he used industrial velcro:
I used industrial velcro, cut to size and lengths to make it happen. In this case the shoulder/bicep is hanging from “garter” velcro attached underside of the chest and back plate shoulder.