Costuming:ARC Jesse EU

From 501st Legion Databank
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ARC Jesse (Phase II) — Realistic
ARCJesseR FullNEWER.png
Model (BuilderTKID), Photo by Hunter Smoke


Clone-Trooper-Detachment.png

Description: ARC Jesse (Phase II)
Prefix: AR
Detachment: Clone Trooper Detachment
Context: “Hot Toys ⅙ Scale Figure”

CT-5597, nicknamed Jesse, served in the 501st Battalion and was eventually promoted to ARC Trooper. Jesse continued to serve with the 501st through the Siege of Mandalore and Order 66 at the end of the Clone Wars.


Please note that this costume is also eligible for membership in The Rebel Legion, although adjustments may need to be made for RL approval.

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.


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.


RepublicCog.png General Construction Notes
  • Realistic Phase II style armor with ARC trooper additions.
  • As previously noted, all armor is constructed from rigid material such as fiberglass, plastic, resin, Sintra, vacuum-formed ABS, firm rubber, metal, or similar.
  • All armor pieces are painted white with dark blue details and a matte finish, unless otherwise noted below.
    • All paint details are scaled proportionally to armor.
  • Armor is weathered in shades of grey, with painted sections scuffed to show underlying white, closely matching figure references.
  • All pieces are scaled proportionally to the wearer.





ARCJesseR Helmet.jpg Helmet
  • Forehead features Republic Cog painted dark grey.
    • Cog upper half is split by mohawk, and bottom is cut off by brow band.
  • Rear of helmet dome features inset band.
  • Brow band is painted black.
  • Helmet features inset cheek wells, painted dark blue.
  • Smokey black visor obscures wearer’s face.
  • Helmet frown is painted primer gray.
    • Wire or plastic mesh is utilized inside the helmet to cover the open pieces of the frown.
  • Dark blue is painted around the visor, with a vertical line between the frown and the chin.
  • Chin vocoder is painted black.
  • Aerators are painted black with chrome mesh in the center.
  • Six black vents are present under each cheek well.
    • Vents are not recessed.
  • Ear cap is grey with black border line.
    • Ear cap has three vertical bumps.
    • Valleys between bumps are painted black.
  • Rear of helmet features raised white circular section.
    • The raised face features an inset division symbol with dark blue in the grooves.
  • Rear of helmet features dark grey vertical vent.


OPTIONAL Level two certification (if applicable):
  • Helmet has the appearance of a neck ring.





Clone trooper neck seal.jpg Neck Seal
  • Neck seal is black in color with vertical ribbing or smooth in appearance.
  • No logos or labels are visible.
    • If the seal is not incorporated as part of the undersuit, a balaclava or other similar covering is acceptable.





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





ARCJesseR Pauldron.jpg Pauldron
  • Realistic style pauldron made of leather or leather like material; animated version is not acceptable.
  • Pauldron base is black.
  • Pauldron features four raised trapezoidal panels across the front.
  • Shoulder covers have three raised panels on either side.
    • Panels over right shoulder are painted blue.
    • Panels over left shoulder are painted light grey.
  • Triple ammo pouch hangs off pauldron covering the right pectoral.
    • Pouch is black with three silver fasteners.





ARCJesseR Shoulders.png Shoulder Armor
  • Shoulders are symmetrical.
  • Shoulders are tear drop in shape with all rounded edges.
  • Shoulders feature dark blue vertical stripe at the center of the armor.





ARCJesseR Biceps.jpg Bicep Armor
  • Biceps feature dark blue vertical stripe on outside face of armor.
  • There is a recessed area on the lower area of the back of the arm.
  • The outside of the bicep has a hard line edge at the front that turns in.
  • The inside of the upper arm is rounded.
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.





ARCJesseR ElbowsNEW.jpg Elbow Armor
  • Elbow armor features silicon, urethane, or similar flexible material for the strap.
    • Strap may be functional or cosmetic, with black elastic holding the elbow armor to the wearer.
  • Elbow straps have raised detail lines at the top and bottom of the strap.
  • Armor has two parallel dashed detail slots on each outside edge of the elbow at the strap connection.
  • Armor features a groove going around the perimeter of the elbow armor.





ARCJesseR Gauntlets.jpg Forearm Armor
  • The left forearm has the following specific details:
    • Topside with raised greeblie is painted dark blue.
    • Underside is painted white and includes a one inch dark blue stripe that runs along the perimeter of the dark grey portion of the gauntlet, with a spacer of light grey paint between the colors.
    • Top half of gauntlet and front wrist end is painted dark grey.
    • Includes a comm-pad with four square buttons on the left side of the gauntlet.
      • Buttons are painted or back lit from elbow to wrist in the following order: Green-Red-White-Yellow.
    • Mounted on the top of the left forearm is a small dark steel rocket.
  • The right forearm has the following specific details:
    • Six individual raised rectangular segments with recessed detailing. The segments widen and lengthen as they progress from wrist to elbow opening.
      • Segmented section is painted dark blue.
    • There is a recessed seam line on both sides of the forearm, running from wrist to elbow
    • Sides of the forearm feature recessed seam lines, that run from wrist to elbow.





ARCJesseR Handplates.png Hand Plate Armor
  • Hand Plates are symmetrical.
  • Hand Plates have a top curving ridge that comes to a point over the index or middle finger just past the main knuckle of the hand.
  • Armor is weathered with various scuff marks and 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.





ARCJesseR Chest.jpg Chest Armor
  • Two detail slots on right breast.
  • Chest and back armor match together at the sides with no open gap.
    • A seam line is present.
  • Shoulder straps are placed underneath the chest to connect to the back.
  • Shoulder straps are slotted into the detail ridges of the top connection points.





ARCJesseR OuterChest.jpg Outer Chest Armor
  • Dark blue stripe runs vertically down armor, tapering as it goes downward.
    • Stripe breaks near bottom, leaving a small dark blue section at the bottom edge.
  • Outer chest armor fits flush to chest armor. A small gap is allowed.
  • A recessed groove line is present along the center.
  • Bottom edge of outer chest armor extends past the bottom of the chest armor.





ARCJesseR Back.jpg Back Armor
  • Rear center plate has detailed area that contains four circles, two parallel lines in the bottom left, and a rectangular vent detail in the bottom right.
  • Back and chest armor match together at the sides with no open gap
  • A seam line is present.
  • Shoulder straps are placed underneath the back to connect to the chest.
  • Shoulder straps are slotted into the detail ridges of the top connection points.





ARCJesseR Backpack.jpg Backpack
  • Pack is painted black with dark brown and dark grey detailing.
  • Outer face of pack features the following brown detail panels:
    • Upper right has two raised rectangles stacked vertically.
    • Upper left features raised circle rim with inset center.
    • Bottom features large brown raised panel with four secondary raised details on top.
  • Right side of pack features two tubes with bulbous ends.
    • Left tube features large cylindrical top with horizontal grooves painted dark grey.
      • Bottom half of left tube is ovular with horizontal grooves, painted dark grey.
    • Right tube is painted black with a curved bottom facing outward, with the appearance of a shower handle.
      • Right tube has gumdrop shaped topper.
  • Sides of pack feature two raised horizontal rectangles.
  • Bottom sides of pack feature cylindrical raised details on either side.





ARCJesseR AbUPDATE.JPG Abdomen Armor
  • Two inset lines divide the abdomen armor into segments.
  • Four holes, approximately ¼ inch in diameter, are present in each inset line.
  • Abdomen armor goes underneath the chest and back armor.
  • Armor is seamless at the sides and closes in the back.
    • A raised armor plate covers the seam line and hides rear closure.





ARCJesseR Cod.jpg Codpiece and Posterior Armor
  • Codpiece and Posterior armor connect at the hips.
    • Hip connection should have the appearance of a button greeblie, and the correct detailed shape at the connection point.
  • Armor is weathered with various scuff marks and shades of grey.





ARCJesseR Belt.jpg Belt
  • Belt front between boxes has three vertical rectangular indents which are spaced apart by two protruding rectangular details.
    • The rest of the belt has a flat surface with raised edging on the top and bottom that runs along the belt edges.
  • Eight belt boxes are attached to the belt with four on each side, and an extra ammo pouch on either side.
    • The two largest boxes are in front with an angled top surface that is higher towards the center of the belt.
    • The two smallest boxes are located behind the front boxes, about ⅛ inch behind the front boxes and have an angled end on top.
    • The two medium sized matching boxes, with flat top covers, are about ⅛ inch from smallest boxes.
    • Left rear box is spaced closer to detonator and has two square buttons in the top left corner, and two dashed indented detail marks on the bottom right.
    • Right rear box is spaced closer to detonator and has a bar with two small cylinders centered and two dashed indented detail marks on the bottom left.
    • Boxes are notched on back and fit flush to belt.
    • Ammo pouches are located between rear box and the detonator, connected to the main belt.
      • Ammo pouches have two slots with vertical covers, and silver fasteners.
  • A detonator is centered and attached to the back of the belt.
    • Detonator tube is about 2 ¼ inches in diameter with wider detailed end caps.
    • Seven horizontally aligned square buttons are on the left side of the tube when viewing from behind.
    • Detonator connects to back of belt without any visible clips and is firmly secured in horizontal position.


OPTIONAL Level two certification (if applicable):
  • Back of belt behind rear boxes has horizontal ribbing.





ARCJesseR HolstersNEW.jpg Holsters
  • Realistic style symmetrical holsters, painted dark grey.
  • Holsters use a light grey strap going up to the belt for attachment.
  • Inverted triangular detail is present on front facing edge near top of holster.





ARCJesseR ThighBoxes.jpg Thigh Boxes
  • Thigh boxes are painted dark grey, and are connected to the armor with “X” shaped dark blue belts.
    • Belts feature a second dark blue section on top creating a tiered effect.
    • Belts are made of leather or leather like material.
  • Thigh boxes sit inside of large black pouches that contour to thigh box shape.
  • Top flap features a recessed vertical black stripe in center, with two raised horizontal rectangular details present at the bottom of the recessed stripe.





ARCJesseR Kama.jpg Kama
  • Kama is made of matte vinyl or leather like material with canvas or cloth backing.
  • Kama is white with grey details and black edge trim.
    • Dark grey goes around Kama edge, with thicker line at the bottom.
    • A second dark grey line goes around Kama leaving small white space between it and the dark grey edge.
    • Black trim is fabric with visible texture.
  • Bottom corners of Kama are rounded.
  • Front edges of Kama line up with inside edges of belt boxes.
  • Rear edges of Kama are separated in the center of the posterior armor by approximately four inches.





ARCJesseR ThighsNEW.jpg Thigh Armor
  • Front of thigh armor has a flat triangular area near the knee.
  • From the top of the triangle a ridge line travels up the front of the thigh to the top edge.
  • Rear of the thigh has an indention.
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.
  • Outside of lower edge comes to a point.
  • Inner lower edge is rounded.





ARCJesseR Knees.jpg Knee Armor
  • Armor is painted dark grey with white detail line.
    • White stripe is present on knee, following top edge of armor.
  • Knee armor wraps around the front of the leg.
  • From the top center a raised vertical detail is present.
  • Knee armor is strapped to the leg via a white strap with a raised center area that wraps around the leg and connects on both sides of the knee.
    • Center strap is primer gray.
  • Connection between the knee and the strapping has a detailed clip.





ARCJesseR Shins.jpg Lower Leg Armor
  • Top and bottom edge of armor is painted white, with white vertical stripe in the back of armor.
  • Lower legs are mirror images of each other.
  • Additional layer of ARC armor is present, covering regular lower leg clone armor.
  • Front of armor has two cutout trapezoidal details, exposing interior armor details.
    • Top recess features triangular panel matching regular clone lower leg armor, following the recess at the top of the shin armor.
  • Front of armor has vertical groove line starting at the split line between the two inset trapezoids.
  • Rear of shin features raised bands that continue from the front of the shin, running the full circumference of the shin armor.





ARCJesseR Boots.png Boots
  • White, ankle high or tall enough to cover the ankle and eliminate any black undersuit visible at the ankle.
  • Boots are laceless.
  • Boots have center strip that runs from toe to ankle, flaring towards the ankles.
    • Two rectangular panels are present on top of the boot.
  • White band wraps across both angles with circular protruding discs on either side.
  • There are no markings or labels from the shoe makers.
  • Boot soles are flat.
  • Boot soles are colored primer grey.





ARCJesseR BootArmor.png Boot Caps
  • Boot Caps are painted dark grey.
  • Armor attaches to boots without visible straps.
  • Armor does not have visible details.





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.



CRL side arms.jpg DC-17 Hand Blaster

Manufactured by BlasTech Industries, DC-17 pistols are carried in quick-release holsters. They are widely recognized for their unusually high stopping power and firing rate.

  • The number of pistols carried is dependent on the amount of holsters.
  • This is the realistic variant of the DC-17 blaster.





DC15 carbine.jpg DC-15S Blaster

Manufactured by BlasTech Industries, the DC-15S is smaller in scale than the DC-15A blaster rifle. Although it has a shorter range than that of the “A” model, it is easier to handle with a higher rate of fire and features a folding stock for braced firing.

  • Realistic Clone Style DC-15S Blaster.
  • Blaster may be scratch built out of plastic, wood, metal or cast in resin.
  • Blaster has realistic Episode II or Episode III details:
    • Wire frame sight.
    • Folding stock.
    • Twelve radiator fins evenly spaced along the length of barrel.
    • Igniter detail knobs.
    • Charge magazine clip on right side.
  • Total length is approximately 26 inches (66 cm).
  • Because of the scale, the Hasbro version is incorrect.


OPTIONAL Level two certification (if applicable):
  • Charge magazine detail on clip is metal to gun metal grey in color.
  • Detail bolts and screws are metal to gun metal grey in color.
  • Igniter knobs have some copper coloring.
  • Blaster is weathered.
OPTIONAL Level three certification (if applicable):
  • Functioning Blue LED is installed in barrel.





DC15 rifle.jpg DC-15A Blaster Rifle

Manufactured by BlasTech Industries, the DC-15A is a Tibanna gas cartridge powered weapon. Hyper-ionized blue plasma bolts are more than capable of penetrating armored units. Exceptionally effective against both droids and contemporary targets.

  • Realistic Clone Style DC-15A Blaster Rifle.
  • Blaster rifle is scratch built out of plastic, wood, metal or cast in resin.
  • Blaster has realistic Episode II or Episode III details:
    • Flip up sight in down position.
    • Ten radiator fins are evenly spaced along the length of the barrel.
    • Power setting adjuster detail lever.
    • Sniper Scope attached under rifle in storage position.
    • Charge magazine clip on left side.
    • Igniter detail knobs.
  • Total length is approximately 55 inches (139.7 cm).
  • Because of the scale, the Hasbro version is not allowed.


OPTIONAL Level two certification (if applicable):
  • Charge magazine detail on clip is metal to gun metal grey in color.
  • Detail bolts and screws are metal to gun metal grey in color.
  • Igniter has some copper coloring.
  • Power setting adjuster detail lever is metal or gun metal grey.
  • Sniper scope is metal or gun metal grey.
  • Blaster is weathered.
OPTIONAL Level three certification (if applicable):
  • Functioning Blue LED is installed in barrel.







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.