Costuming:91st TCW P2

From 501st Legion Databank
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91st Recon Grunt (Phase II)
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Model CT-_____, Photo by Edgar Guzman


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Description: Clone Trooper — 91st Recon
Prefix: CT
Detachment: Clone Trooper Detachment
Context: Star Wars: The Clone Wars, Season 4
The 91st Mobile Reconnaissance Corps, led by Jedi General Adi Gallia and Clone Commander Neyo, served in many battles over the clone wars. During the battle of Patitie Pattuna, the 91st defended against General Grievous aboard Adi Gallia’s Republic Cruiser. Although the cyborg won the battle, the 91st put up a tough fight.


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

In the page below, items listed in blue are recommended features that will improve the quality of the costume. Items listed in red are intended to further enhance the finished costume.

Special Notes:
• The “Animated” armor design, seen in 2008 The Clone Wars Cartoon Series, differs from the “Realistic” armor design used to create characters from the theatrical films, video games, and graphic novels. See this thread at 501stclonetroopers.com for the differences between the sculpts. (This may require an additional forum account.)
• Armor parts shall be made from fiberglass, ABS (Acrylonitrile Butadiene Styrene), HIPS (High Impact Polystyrene), or a similar rigid material. This includes vacuum formed plastics as well as properly finished and smoothed 3D printed armor forms. See this thread at 501stclonetroopers.com for examples of acceptable and unacceptable levels of 3D print finishing.
• All numerical measurements given in CTD CRLs are approximate. Measurements should be followed as closely as possible while not affecting the proportionality of costume details. Proportionality should take precedence over exact measurements.


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.


  • This document is not intended to be a detailed how-to on costume construction; rather a visual guide to be used for 501st costume approval. Details on construction may be found on the respective costume detachment web forum.
  • GMLs uncertain about an aspect of submitted costume shall post questions in the appropriate DL/GML peer review section of the Legion forum.
  • Measurements given in this document are intended to be approximate and generalized; not criteria for approval.
  • Requirements for all 501st costumes are proportional to the wearer in scale, fit and size.
  • Text descriptions are only one part of the guideline. GMLs and costumers must consider both text and pictures (CRL and Reference) when reviewing the costume.


Required Costume Components

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


91Grunt Helmet.jpg Helmet
  • Phase II animated style helmet.
    • Movie style helmets are not combined with animated armor.
  • Helmet is painted matte or satin white.
  • There is a Phase II style mohawk on top of the dome.
  • A brick red “91st Recon Corps” logo is present on the front right quadrant of the dome.
    • This symbol is made of a large circle, with a white vertical line in the center and smaller white circle towards the top center.
  • A thin black line is present above the brow line of the helmet, and goes around the full circumference.
  • The frown has six removed teeth spaces.
    • Fine black mesh is utilized inside the helmet to cover the open pieces of the frown.
  • Ear caps are dark grey.
  • Vocoder is dark grey.
  • Aerators are black with a grey center circle.
  • Rear helmet indented stripe is painted grey.
  • There are six black vent stripes on each side of the helmet.
  • Black eye lens extends down to the frown area.
    • Lens obscures the wearer’s eyes.
  • Armor is weathered with shades of grey.





TC animated neckseal.jpg Neck Seal
  • Neck seal is black in color with no ribbing.
  • No logos or labels are visible.


OPTIONAL Level two certification (if applicable):
  • Neck seal closes in the front via two small black snaps.
  • A black balaclava is worn with the neckseal.





TK anh stunt undersuit.jpeg Under Suit
  • Black non-textured material, either one-piece or two-piece construction with no visible zippers or logos.




91Grunt Shoulders.jpg Shoulder Armor
  • Phase II animated style shoulder armor.
  • Armor is painted matte or satin white.
    • Left shoulder armor is painted brick red, with a thin white border around the edge.
    • Brick red section is scuffed, showing underlying white.
  • Armor is weathered with shades of grey.




91Grunt Biceps.jpg Upper Arm Armor
  • Phase II animated style upper arm armor.
  • Armor is painted matte or satin white.
  • A brick red “91st Recon Corps” logo is present on the exterior of the right bicep.
    • This symbol is made of a large circle, with white vertical line in the center and smaller white circle towards the top center.
  • Armor is cylindrical with no rear indent.
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.
  • Armor is weathered with shades of grey.




91Grunt Forearms.jpg Forearm Armor
  • Phase II animated style forearm armor.
  • Armor is painted matte or satin white.
  • Right forearm has a compad with 6 raised buttons, and a larger rectangle above them.
    • A smaller raised section is closest to the elbow.
  • Elbow armor sits flush with the forearm armor.
  • Armor is seamless on the outside edge.
    • Due to the shape of the armor, a butted seam is acceptable on the inside if needed.
  • Armor is weathered with shades of grey.


OPTIONAL Level two certification (if applicable):
  • Elbow plate is detached from the forearm.
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.




91Grunt Hands.jpg Hand Plates
  • Phase II animated style hand plates.
  • Armor is painted matte or satin white.
  • Hand plates are mirror images of each other.
  • Hand plates have an angled peak that comes to a point over the index or middle finger, just past the main knuckle of the hand.
  • Armor is weathered with shades of grey.





Generic-black-gloves.jpg Gloves
  • Black over the wrist gloves made of leather, nylon, or other low pile fabrics.
  • Gloves cover any exposed skin.
  • Gloves do not show any labels or logos when the armor is worn.




91Grunt Chest.jpg Chest Armor
  • Phase II animated style chest armor.
  • Armor is painted matte or satin white.
  • Lower portion of the chest has a squared notch for the abdomen armor to fit into.
  • A brick red “91st Recon Corps” logo is present on the bottom center of chest armor. Only the top half of this logo is present, and lines up with matching design on abdomen armor.
    • This symbol is made of a semicircle with a vertical white center line, with a smaller white circle present at the base of the chest.
  • Chest and back plate match together at the sides and shoulders with no open gap.
    • Butted seam lines are permitted if needed.
  • White shoulder straps fit into the top of the chest and back.
  • Armor is weathered with shades of grey.




91Grunt Back.jpg Back Armor
  • Phase II animated style back armor.
  • Armor is painted matte or satin white.
  • Back armor has a detail plate consisting of four grey circles and five grey horizontal bars.
  • Chest and back plate match together at the sides and shoulders with no open gap.
    • Butted seam lines are permitted if needed.
  • White shoulder straps fit into the top of the chest and back.
  • Armor is weathered with shades of grey.





91Grunt Abs.jpg Abdomen Armor
  • Phase II animated style abdomen armor.
  • Armor is painted matte or satin white.
  • Top edge of the armor is squared off to match the chest armor.
  • A brick red “91st Recon Corps” logo is present on top center of abdomen armor. Only the bottom half of this logo is present, and lines up with matching design on chest armor.
    • This symbol is made of a semicircle with a vertical white center line.
  • The abdomen armor protrudes out in the middle to match the shape of the chest armor.
  • The abdomen armor joins at the rear and the join is covered by a center plate.
  • Armor is weathered with shades of grey.




91Grunt Cod.jpg Codpiece and Belt front
  • Phase II animated style codpiece and belt front armor.
  • Armor is painted matte or satin white.
  • Belt is approx. 3" tall and divided into 1.75" wide segments.
  • The front segments have a key/slot detail.
  • Belt boxes are mounted on either side of the front “buckle” section.
    • The top side of the box is tapered outward.
    • There is an inset detail near the top of each box.
  • Codpiece and Posterior armor connect at the hips.
    • Butted seams are permitted at this connection if needed.
  • Armor is weathered with shades of grey.




91Grunt Posterior.jpg Posterior Armor, Belt Rear and Detonator
  • Phase II animated style posterior armor, belt and detonator.
  • Armor is painted matte or satin white.
  • Belt is approx. 3½ inches tall and divided into 2 and ¼ inch segments.
  • Cod and Posterior armor connect at the hips.
    • Butted seams are permitted at this connection if needed.
  • Detonator is centered on the back of the belt with no control buttons.
    • The detonator has two lines set in approx. 1 inch from the edges.
      • Lines may be recessed or painted on.
  • The center of the detonator end caps are painted grey.
  • Armor is weathered with shades of grey.


OPTIONAL Level two certification (if applicable):
  • Detonator lines are recessed.




91Grunt Thighs.jpg Thigh Armor
  • Phase II animated style thigh armor.
  • Armor is painted matte or satin white.
  • Front of thigh armor has a flat triangular area near the knee with a notch cut out for the knee armor.
  • From the top of the triangle a ridge line travels up the front of the thigh to the top edge.
  • The upper outer edge has an angled section.
  • Armor is weathered with shades of grey.


OPTIONAL Level two certification (if applicable):
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.





91Grunt Shins.jpg Lower Leg Armor
  • Phase II animated style lower leg armor.
  • Armor is painted matte or satin white.
  • The front of the armor has a triangular detail just below the knee and a hard ridge line down the front of the shin.
  • Back of the lower legs have an indentation just under the calf that extends down to the ankle.
  • Knee armor sits flush with the front of the lower leg armor.
  • The outside of the calf is seamless.
    • A clam shell opening on the inner seam is acceptable.
  • Armor is weathered with shades of grey.


OPTIONAL Level two certification (if applicable):
  • Knee armor is detached from the lower leg.
  • Armor is seamless with a trap door access through the indent in the rear of the lower leg.





TC animated boots.jpg Boots
  • White, ankle high or tall enough to cover the ankle and eliminate any black undersuit visible at the ankle area.
  • Boots are laceless and have flat soles.
  • Boots have a center strip running from the toe to the ankle.
  • A strap across the top of the foot has two (2) flat white discs on either side of the foot, terminating the strap.


OPTIONAL Level two certification (if applicable):
  • Boots have accurate notched sole.




Optional Accessories

Items below are optional costume accessories. These items are not required for approval, but if present appear as described below. If adding in an accessory after initial approval, the item still needs to be submitted to local GML for approval before use.


CRLdc15s-animated.jpg DC-15S Blaster Carbine (animated style)

Manufactured by BlasTech Industries, this weapon is commonly carried by the Troopers of the Galactic Republic.

  • This is the animated variant of the DC-15S blaster rifle.




Dc15a Animated.jpg DC-15A Blaster Rifle (animated style)

Manufactured by BlasTech Industries, this blaster is the standard issue weapon carried by the Clone Troopers of the Grand Army of the Republic.

  • This is the animated variant of the DC-15A blaster rifle.







This document and all of the images within were created by and are the property of the 501st Legion. Other media owned by Lucasfilm Ltd and Disney are used under authorization. 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 follows generally accepted ground rules for Star Wars fan groups. Star Wars, its characters, costumes, and all associated items are the intellectual property of Lucasfilm. Copyright and Trademark Lucasfilm Ltd. All rights reserved. Used under authorization.