Impressive work from Instructables user parrster, who meticulously crafted the twenty-three separate pieces for his son's Star Wars "clone trooper" costume, this year, mostly from cardboard and papier-mâché.
Probably one of the more challenging craft projects I've undertaken with the kids, to fabricate a childs full Clone Trooper costume (including helmet) from rigid boxboard sheets. Below is the end result and a bit about how it was done. The model is my ten year old son.
Star Wars Costume Evolution: Stormtroopers - Infographic