Halloween could not have come sooner this year for these guys. They call themselves, the “Carbon Fiber Stormtroopers”.

Leonard Carson, an engineering technician for San Diego Composites, had been toying around with this idea of a carbon fiber Stormtrooper for a long time. He finally convinced three of his engineering co-workers to jump on board with turning this carbon fiber idea, into a carbon fiber reality. Being the huge Star War fans that they are, and often working with the material for their composites company, I’d have to guess not too much convincing was necessary.
And so the thought process began. There was a lot to consider for this project, especially cost. We all know how pricey our precious carbon fiber material can be. Other than that, the four troopers needed to think about the most logical tooling, finishing and best processes to use. They used all Grade A materials from a local supplier, and their employer, San Diego Composites, donated some resources to the project as well.

The President at their company, San Diego Composites, actually loved this idea and was extremely supportive of the entire project. Leonard said, “He actually wants one to display in our lobby! After the last finished part we talked to him about how much time and money we’ve spent and he did a cost calculation according to our company’s standards. He came up with the cost to cover the time and materials, tooling and 4 complete suits. We’re lucky he didn’t do the calculations ahead of time haha.. we never would’ve started.” While we can’t say the actual amount that was been spent to produce these suits, lets just say you can optionally purchase a pretty nice car as an alternative.
Browse below to see the final result. You can tell these guys had a great time showing off their work!






Left to Right: Jon Blackler, Kevin Proum, Len Carson, Daniel Avina
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These are really awesome suits! Overall it’s a good article, but I feel that the picture with the cigarette is a little tasteless, especially since these characters are from a child-friendly film.
What is family friendly about people with lazer guns shooting each other and there is killing! Your definition of child friendly is scary.
Star Wars – Child friendly? Is that a joke? What movies were you watching?
…they blow up an entire planet, and you’re worried that one of them will get lung cancer?
Massively over sensitive reality recluse ahoy!
Jen, you obviously haven’t seen Star Wars. Spoiler alert: The stormtroopers are the bad guys. Not only do they smoke, but they also drink excessively & kick puppies.
Its not a cigarette, its a Death Stick.
shut the f#!k up jen
Jen, with all the people getting killed or chopped up in the movies, sex slaves, etc, I’m fairly sure there’s worst things to worry about.
Note that I hate cigarette as I’ve had 3 people close to me die as a direct result of their cigarette use, but still… it ain’t so bad for just that picture.
Have to agree with Tim on this, “Child friendly film”, did you see the movie? Arms being cut off, people (and Jawas) burned, mass slaughter, whole plants being blown up.
The armor is beyond cool, i would love to show a set of it off at a big trade show in LV in January
Planets, sorry, I could care less about plants being blown up, that is just a fun Friday
afternoon
Actually smoking is canon to the Lucasfilm franchise, seen in the Mos Eisley bar and again in The Clone Wars movie which preceded the TV series. I have not seen the cartoons but I have heard that it was also canonized in the cartoons of the 1980s. Also Tobac is canon in the books, as early as the Zahn novels.
I’m a complete non-smoker by the way.
The tobacco isn’t a problem, you’re over-sensitive.
Awesome job! Any tests on actual protective value?
Totally Badass!! If I’m not mistaken, It looks like they went with the Return of the Jedi fit for the armor.
I SO wish I had the money to get one.lol.
A little short for Storm Troopers aren’t they?
Was thinking the exact same thing/quote.
…Though these are indeed awesome.
For a second there, I thought these were Shadow Troopers ( TX ).
Next up… Carbon Fiber Boba Fett, Chewbacca, AT-ST Walkers, X-Wing, Darth Vader, the Red Guards, Y-Wing, Yoda, and last but not least Jabba the Hut!
How much and where do I order?
These trooper have stylish taste in shoes.
Looks really cool but it’s too bad they based it off of the crappy Rubies armor. They should have researched the armor a little more…
Oh man,you’re right ! I knew something just didn’t look right about these. The loose undersuits and tennis shoes didn’t help either. Would the 501st accept these ?
I would LOVE a set of Carbon Fiber Boba Fett gear! If your reading this guys…
Or Clone Trooper armor
I would so love to have one of these sets of armor in my Star Wars costuming collection. It would replace my Shadow Trooper armor in a heartbeat.
You guys did a fantastic job!
Shut up and take my money!
jabba’s smoking out of a hookah, add grievous to the carbon fiber list
I just want to know how much those cost and how I could get or make one =)
SHUTUP AND TAKE MY MONEY!
Must be nice to be the 1% that can waste a ton of money on this.
There’s 4 people will survive the zombie apocalypse.
Ben: In what way are these guys the 1%? You sound as much of a whining, leftist killjoy as Jen. Presumably you’re part of majority of the 99% who won’t get a job, and expect to be handed everything on a plate.
This is how the Storm Trooper Armor should had looked like in the whole saga! White has zero camuflage value almost in any enviroment at all (maybe in Hoth)… You gotta do other characters!
You guys getting down on Jen should think about one thing, if Jen is a member of the 501st (www.501st.com) then the smoking pic is a no go for the club (not saying the pictured person is a member or not) A note on the armor, that is awesome. Most of the comments I’ve read that aren’t here say pretty much the same thing (for both items) Just remember that we 501st’ers go by different “in-public” rules than most other clubs.
Who gives a sh*t about the 501st. Oversensitive whiners.
These aren’t the comments you’re looking for.
Star wars is definitely a kids movie! Just because we’re all adults now doesn’t mean we didn’t watch it a million times while growing up. I must’ve spent the better part of my early youth watching the same VHS copies over and over.
I am wanting to sell an Anakin Skywalker life size statue that JC Penny built in ’99 from the frist episode. It has never been played with and has been kept clean. I still have the box it came in. From my reasherch there has been less then 300 of them made so it’s a hard find especially for one in this good of condition. I know it doesn’t really have to do with this photo or whats being talked about but I need to sell it. If you or someone you know is interested please e-mail me at universal_royal_princess2003@yahoo.com. I can e-mail pics of it. Thank you!
DORKS!!!
/My kind of dorks….
Man, I would love to see if these guys could make me an Arc Trooper Style armor like this haha xD these are really awesome!!!
I think it is awsome that they made them and had enough sense to find a backer. I am put their picture on my prolfile. I do love me some men in metal, JangoFett, Troopers, Boba Fett, Han; They are all very hot.
-and the typo fairy attacks again-, lol.
I am going to put their picture on my profile.