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Stormtrooper, Return of the Jedi
TK rotj.jpg
Model TK-4625, Photo by Jason Kreis


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Description: Stormtrooper, Return of the Jedi
Prefix: TK
Detachment: First Imperial Stormtrooper Detachment
Context: Episode VI: Return of the Jedi

"An entire legion of my best troops awaits them". - Emperor Palpatine (ROTJ)


Outfitted with newly designed armor and the new series of BlasTech E11's, the Stormtroopers were the main garrison for the newly constructed, second Death Star. The Emperor stationed the Empires’ finest Legion of Stormtroopers to defend the defense shield for the Death Star. They were the main strike unit during the battle on the Forest Moon of Endor.


These highly trained elite soldiers cannot be bribed or swayed from their dedication to the Empire.

The Stormtroopers are not only the first strike team units sent into critical combat situations, but are also assigned to keep a watchful eye over the Imperial officers who might betray the Emperor’s cause.

Garrisons of Stormtroopers are stationed on worlds throughout the Galaxy to keep order, and stop any Rebel uprisings.

Even though the Stormtroopers are an independent unit, having their own command structure, ranking system and support facilities, they still serve on Imperial vessels, and operate along side the Imperial army and navy.

The Stormtroopers are shielded by hardened, plastoid,composite armor, fitted over a black environmental body glove, with a built-in life support system. The imposing white armor not only protects them from harsh environments, but also gives limited protection from blaster fire.

Stormtroopers carry an array of equipment and weapons ,wielding blaster rifles and pistols with great skill.

The Stormtroopers, having the combined training and battle tactics of both an Army soldier and a Marine, makes them highly adaptable and a very skilled force.


The 501st approval requirements are listed in black.

FISD Defines two additional, optional levels of costuming excellence. In the page below, requirements for Level 2 "Expert Infantryman" are listed in blue. Requirements for Level 3 "Centurion" are listed in red.

  • Those armor pieces without blue and/ or red text are by default considered the highest level.
  • Please visit the FISD web site for a full description of these standards.

For 501st membership only the requirements in black need to be met.

Special Notes:

  • Visit the Frequently asked questions page for information on the Rubies Supreme Stormtrooper costume.
  • Blasters are not required for legion membership per our weapons policy.
  • The armor parts shall be made from one of these types of materials or like materials: White fiberglass, ABS (Acrylonitrile Butadiene Styrene), HIPS (High Impact Polystyrene), or Polyvinyl chloride (PVC).
  • FX armor may not be used for Level 3 approval.
  • FX helmet is no longer permitted for new approvals.


This Visual Guide has been reviewed by the detachment staff and the LMO team and is certified for use as a minimum approval guideline for GMLs. GMLs are free to approve this costume type.
  • Any uncertainties or questionable aspects of the submitted costume should be brought to the appropriate DL/GML peer review section of the legion forum.
Required Costume Components

The following costume components are present and appear as described below.

TK rotj helmet.jpg Helmet
For 501st approval:
  • Traps (trapezoids on dome of helmet) and tears (area beneath the corners of eye lenses) are gray.
  • Rear traps and tears have vertical black lines.
  • Lenses may be flat or bubble, smoke or green in color, sufficiently dark enough to obscure the costumer's eyes.
  • The "ear" bars have three or four bumps, and is grey or painted grey, with a black outline.
    • Painting the bumps with rank stripes (Highlighted) in black is optional.
  • Frown is painted black and overlaps the teeth area. Eight total teeth on the frown are cut out.
  • Tube stripes are medium blue, should be 13 per side, but can be between 9 and 16 per side with the curve bends extending backwards.
  • Vocoder (vertically ribbed chin detail) is painted black.
  • Aerators/Hovi mix tips (cylinders on either side of the vocoder) are black or painted black.
  • Tears, traps, and tube stripes should be decals, but can be hand painted, or decals that replicate hand painted.
  • Mesh may be used behind the frown to obscure the face of the wearer.
  • Note: The helmet is accurate in detail and proportion to official references.
    • Many commercially available helmets or those considered disproportionate in size or shape are ineligible.


For level two certification (if applicable):
  • Ears have no visible screws per side.
  • Traps/tears and tube stripes are decals (with the correct ROTJ details), not hand-painted or decals that replicate hand painted.
  • Traps/tears may be either ANH gray or a slightly bluer shade of ANH gray.
  • The ends of the frown are rounded, not tapered to points (not like ANH/ESB) and not squared ended like the ESB MKII.
  • Ear bars have four bumps only, not three.
  • Correct 'Hovi mic' aerator tips.
For level three certification (if applicable):
  • Eye lenses are bubble style and tinted green.
  • Ear bars have only two to three bumps painted in black (rank stripes).
  • Neck trim is of an s-type profile rather than a u-type profile.



TK anh stunt neckseal.jpeg Neck Seal
For 501st approval:
  • Black with horizontal ribs, fitted to the wearer, and extending from the base of the neck to conceal the entire neck.


TK anh stunt undersuit.jpeg Under Suit
For 501st approval:
  • Black non-textured material, either one-piece or two-piece construction with no visible zippers or logos/designs.



TK anh stunt shoulders.jpeg Shoulder Straps
For 501st approval:
  • Shoulder Straps are securely mounted in front and may free float in back. They may be affixed with rivets, Velcro, or adhesive.


For level two certification (if applicable):
  • No visible rivets are allowed.
  • Shoulder straps do not have a flat surface at the ends.
    • Straps are ribbed 100%.
For level three certification (if applicable):
  • These are affixed in the front (no snaps, rivets or brads are visible).
  • These are affixed in the back (no snaps, rivets or brads are visible).



TK rotj shoulderbells.jpg Shoulder Armor
For 501st approval:
  • One on each shoulder. The shoulder bells are considered effectively symmetrical; they may be worn interchangeably on the left and right shoulders.


For level two certification (if applicable):
  • Shoulder bells are rounded at the corners.
  • Shoulder bell straps 1/4"(6.3mm) wide are present, worn higher and are visible across the biceps armor like in ANH.
For level three certification (if applicable):
  • Shoulder bells have foam padding inside.
  • Shoulder bells are slightly pinched and worn slightly higher, compared to ANH/ESB.



TK anh stunt biceps.jpeg Upper Arm Armor
For 501st approval:
  • Biceps are fully closed.


For level two certification (if applicable):
  • Biceps use the overlap construction method.
    • Using the butt joint and cover strips is not allowed.



TK anh stunt forearms.jpeg Forearm Armor
For 501st approval:
  • Forearms are fully closed.


For level two certification (if applicable):
  • No return edge on the inside of the front of the forearm is allowed.
  • Forearms use the overlap construction method.
    • Using the butt joint and cover strips is not allowed.



TK esb handplates.jpeg Hand Plates
For 501st approval:
  • Hand Plates are clam shell style, or snowtrooper-style hand plates and not the trapezoidal design seen in A New Hope.
  • The hand plates are mounted securely over the back of the glove.



TK anh stunt gloves.jpeg Gloves
For 501st approval:
  • Black in color, made of either rubber, nomex, leather, or leather-like material, with no visible straps or logos/designs. The fingers are enclosed, non-textured.


For level two certification (if applicable):
  • Gloves are rubber or rubber like chemical gloves in black.



TK rotj chest.jpeg Chest
For 501st approval:
  • Chest plate overlaps the abdominal plate.
  • A white flexible U shaped gasket or molded lip is present around all edges.


For level two certification (if applicable):
  • Fabric or elastic strip connecting chest to back is either black or not present.
  • AM chest plate is replaced with a more screen accurate version.



TK rotj back.jpeg Back
For 501st approval:
  • Back plate contains a "O II" design.
  • A white flexible U shaped gasket or molded lip is present around all edges.


For level two certification (if applicable):
  • Back Armor has no overlap, or minimal overlap of the kidney plate.
  • AM back plate is replaced with a more screen accurate version.



TK rotj ab.jpg Abdomen Armor
For 501st approval:
  • A white flexible U shaped gasket or molded lip is present around all edges.
  • The Abdomen Armor has a button area that matches the color pattern shown (3 dark blue + 6 charcoal grey or black); buttons are approximately 7/16" (11mm) in diameter. The three dark blue buttons will be the three buttons closest to the belt.
  • Abdomen Armor button detail is inverted compared to ANH/ESB.


For level two certification (if applicable):
  • There are no visible split rivet/brad on the cod/crotch and no visible rivets or brads on the left or right side of the ab plate, unlike ANH/ESB.



TK rotj butt.jpg Kidney & Posterior Armor
For 501st approval:
  • A white flexible U shaped gasket or molded lip is present around all edges.
  • A separate kidney/posterior armor is not allowed - the kidney and posterior are combined/fused to a single plate/one piece.
  • The crotch tab of the butt plate area may or may not have visible snaps.


For level two certification (if applicable):
  • The edges of the hip area should be rounded/curved (not like the straight lines found on the ANH/ESB butt plate).
For level three certification (if applicable):
  • There are no visible side rivets on the kidney plate, unlike ANH/ESB suits.
  • There are no visible snaps, rivets or brads on the crotch tab of the Posterior Armor tab.



ROTJ Belt.jpg Belt
For 501st approval:
  • Belt face is made of plastic (TK ammo belt).
  • The soft belt proper is tightly woven nylon/cordura like/style material or material with a tightly woven nylon/cordura like/style covering. Size is 2.25" (57mm) to 2.5" (64mm) wide. The color is to be white to off-white.
  • The drop boxes dangle from the sides of the front plastic belt (ammo belt) via white straps and are aligned under the plastic tabs of the ammo belt.


For level two certification (if applicable):
  • There are no square buttons covering the belt rivets.
    • There are two rivets, one on each side of the ammo belt.
  • Corners of ammo belt are cut at right angles.
    • Not 45 degrees as in ANH/ESB.
  • Drop boxes are closed in the back.



TK anh stunt detonator.jpeg Thermal Detonator
For 501st approval:
  • (A.K.A. O2 canister) attaches to the center back of the belt. This is an all gray cylinder without silver stickers or silver paint. The cylinder is between 2” (50mm) and 2.68"(68mm) in diameter with white end caps on each end. The white control panel pad faces upwards, with controls/round washer style detail closest to the right end cap. The total length should be approximately 7.50" (190.5mm).
  • The thermal detonator is attached via metal or metallic-appearing clips approximately 1/2" (12.7mm) to 3/4" (19mm) wide.


For level two certification (if applicable):
  • Thermal detonator belt clips are positioned half way between center of detonator and the end cap.
For level three certification (if applicable):
  • The thermal detonator control panel has correct ROTJ details, not ANH/ESB.



TK anh stunt thighs.jpeg Thighs
For 501st approval:
  • Thigh armor is closed in the back.
  • The ammo belt is installed on the bottom of the right thigh.


For level two certification (if applicable):
  • The thigh ammo belt shall be standard rivets.
  • The bottom corners of the thigh ammo belt are rounded off.
  • Thighs use the overlap construction method. Using the butt joint and cover strips is not allowed.



TK anh stunt shins.jpeg Lower Legs
For 501st approval:
  • Greaves close in the back. The trapezoid knee plate (sniper knee plate) is affixed to the left greave and may have two visible brads or rivets securing it to the greave.
  • The AM greaves (shins) shall be on the proper legs, with a new cover strip. The cover strip edge faces the inside of the leg. Note: There is a manufacturer defect with the AM greaves (shins) that may cause you to wear the them improperly. Please see the Tutorial titled :"AM armor shins: the proper way to assemble and wear", on the whitearmor.net


For level two certification (if applicable):
  • Lower legs are constructed using the overlap construction method. Using the butt joint and cover strips is not allowed.



TK anh stunt boots.jpeg Boots
For 501st approval:
  • Boots are above ankle height and made of white leather or leather-like material.
  • Small U-shaped elastic sections on both sides of the ankle.
  • Flat sole with a short heel.
  • No buckles or laces.
  • Jodhpur/ Chelsea-type boots or an equivalent style is acceptable.
    • Elvis or Mariachi boots are not allowed.


For level two certification (if applicable):
  • There is no seam present on the front of the boot.
  • Boots are lightly scuffed.
For level three certification (if applicable):
  • Boots have a white sole.
    • Painted soles are acceptable.


Optional Accessories

Items below are optional costume accessories. These items are not required for approval, but if present appear as described below.

ROTJ holster.jpg Holster
For 501st approval:
  • Holster is made completely of black leather or leather-like material.
  • Holster is worn on the right side of belt.
  • Holster is attached via the straps behind the belt using two fasteners in the middle of the belt.
    • The fasteners may be rivets, snaps, or Chicago screws.
    • Note: the straps are a little longer for the ROTJ holster, then seen on the other Original Trilogy Stormtroopers.


TK rotj e11.jpg BlasTech E-11
For 501st approval:
  • Based on a real or replica Sterling sub-machine gun, scratch-built, or a modified commercial toy Stormtrooper blaster.


For level two certification (if applicable):
  • Folding stock (does not need to function).
  • No ammo counter is present.
  • D-ring mounted on the rear.
  • Correct style scope.
  • No power cylinders on the magazine housing.
  • Scratch-built, resin cast, Hyperfirm rubber cast blasters have a total of (7) U shaped channels on blaster (all holes on barrel are covered).
  • If using the popular commercially available Stormtrooper blasters, you shall grind off the T-tracks and replace them with U shaped channels and cover the open rows of holes (total of 7 U shaped channels in all).
  • Correct greeblies on the left rear area are present (door catch and two "hammers").
For level three certification (if applicable):
  • Hasbro blasters are not allowed, even conversions.
  • Forward D-ring is mounted underneath the front sight on the left side of the barrel.
  • Use of the correct front sight (which differs from ANH and ESB).
  • The scope rail is unique to ROTJ E11 and is not like the normal open ANH/ESB scope rails, but is a solid, one piece, with a unique sight design on the front. The scope connects to the notched out area of the solid rail. The scope is the correct design (as seen in ROTJ), and will attach to the scope rail via one scope mount.
  • The muzzle is unlike the normal ANH style. It is flat with two counter sunk Allen bolts (one located at the four o’clock position and one located at the ten ‘o’clock position).
  • The door catch is correct, not a "close enough" attempt as seen on the Cinemastery blaster.



This document and all of the images within were created by and are the property of the 501st Legion. All other uses are prohibited.

The 501st Legion is a worldwide Star Wars costuming organization comprised of and operated by Star Wars fans. While it is not sponsored by Lucasfilm Ltd., it is Lucasfilm's preferred Imperial costuming group. Star Wars, its characters, costumes, and all associated items are the intellectual property of Lucasfilm. ©2012 Lucasfilm Ltd. & TM. All rights reserved. Used under authorization.

Visit www.501st.com to learn more.
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The 501st Legion is a worldwide Star Wars costuming organization comprised of and operated by Star Wars fans. While it is not sponsored by Lucasfilm Ltd., it is Lucasfilm's preferred Imperial costuming group. Star Wars, its characters, costumes, and all associated items are the intellectual property of Lucasfilm. © & ™ Lucasfilm Ltd. All rights reserved. Used under authorization.