Andrew Ainsworth did not “design” the original Stormtrooper helmet. He was hired to cast a mold based on work that was already done. The actual design was the result of a team effort by people like George Lucas, Ralph McQuarrie, Liz Moore, and Brian Muir. Ainsworth was a work-for-hire that was called in the very last stage of the fabrication of the helmet. He was given designs and clay sculpts, and made a mold based on them. Ainsworth had nothing to do with the actual design of the helmet, and you really ought not to state such things in your articles. No matter how much the nerd community wants to hate George Lucas, the ruling in Ainsworth’s favor was a BAD THING for creators and designers. It basically allowed a work-for-hire to steal someone else’s designs for his own profit.

… and suddenly he talks and throws me off.

Orrrrr… you could buy one rather than spend money on all the tools and materials, unless you are a costume factory or a rich kid with money and time to waste.

I… I don’t think I have the right materials.

ok lemme see if I got this right.
1 - Get your black helmety thing, and coat it with yellow stuff.
2 - Use rasp and carving tools to make yellow stuff into stormtropper shape
3 - mix random amounts of glass fiber, filite, steel, iron and aluminum dust in a little bucket with a mystery liquid.
4 - coat yellow stuff with gray stuff mixture
5 - brush gray stuff with watery gray stuff
6 - carve with handheld grinder, rasp and sandpaper
7 - cut wood pieces with band saw
8 - smear UPOL Easy-1 on mouth piece area and place wood pieces in it
9 - compare to your original
10 - make obscure gestures
11 - vacuum form front
12 - vacuum form back with original 76 tool (wait what? Did we make the back?)
13 - put on one glove
14 - obscure gestures
15 - vacuum form blister eyes
16 - spray with air and compare to original piece
17 - cut and assemble
18 - pose and smile

the smile at the end made ma laugh. This guy is awesome!

Kay now how am I going to make this?