Costuming:CW Vaughn

From 501st Legion Databank
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Captain Vaughn (Phase II)
VaughnFullBody.jpg
Model CC-29007, Photo by A. Ortiz


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Description: Captain Vaughn (Phase II)
Prefix: CC
Detachment: Clone Trooper Detachment
Context: The Clone Wars, Season 7
CT-0292, nicknamed Vaughn, served in the 332nd Company of the 501st Legion. During the Siege of Mandalore, Vaughn was promoted to the rank of Captain and served under Commander Rex during the hunt for Maul in the city of Sundari.


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.


VaughnHelmet.jpg Helmet
  • Phase II animated style helmet with commander attachments that include visor and ear column antenna.
  • Movie style helmets are not combined with animated armor.
  • Helmet is painted matte or satin white with appropriate orange details.
    • The face area of the helmet is painted orange.
    • The front half of the mohawk and dome of the helmet are painted orange with white details similar to the facial markings of Ahsoka Tano.
    • Two symmetrical white diamonds are present on the forehead just above the bottom edge of the center mohawk and extend over side mohawks.
    • Angular white markings are present above the brow line of the helmet and extend to a point over the dome, along the sides of the fin.
    • White markings extend down to meet with white detail markings of the visor.
    • The face and chin of the helmet are painted orange.
    • A maroon or burgundy stripe extends from the bottom of the frown, down the chin and over the center of the additional vocoder detail.
      • The stripe is wider at the top and then tapers to a constant width.
    • A maroon or burgundy stripe is present along the bottom edge of each side of the visor.
  • There is a Phase II style mohawk present on the top of the dome.
  • Two additional, white mohawks are present on the top of the dome, one on each side of the center mohawk.
  • Brow band is painted dark grey.
  • A visor sits on the brow band and has arms that extend around indented band just behind the ear columns.
    • The top and sides of the visor are painted maroon or burgundy with white detail markings.
    • The front edge and underside of the visor are white.
  • Black eye lens extends down to the frown area.
    • Lens obscures the wearer’s eyes.
  • 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.
  • There are six black vent stripes on each side of the helmet.
  • Rectangular communication device is mounted to the left ear of the helmet and is painted grey.
  • A stalk extends to just under the highest point of the helmet and extends inward to a sharp point.
  • A dark grey antenna is attached behind the right ear column and extends above helmet.
  • Antenna base aligns with area between back recessed area and top of ear cap.
  • An additional chin piece is presented over the vocoder and is painted matte or satin white.
  • Vocoder in chin indentation is painted black or dark grey.
  • Black aerators with grey center detail are located in the two front aerator tube indentions.
  • Armor is weathered with shades of grey.
  • A spotlight may be located on the left side of the helmet above the visor.
    • The spotlight faces forward
    • Spotlight is painted white with black eye.




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.



VaughnShoulders.jpg Shoulder Armor
  • Animated style Phase II shoulder armor.
  • Shoulders are tear drop in shape with all rounded edges.
  • Shoulder armor is not symmetrical with each slightly curving back at the bottom.
  • Armor is painted blue.
  • The left shoulder has an antenna located near the top edge of the armor.
  • Antenna is painted grey.
  • Armor is heavily weathered with shades of grey scratches and scuff marks.
    • Scuff marks and scratches expose the underlying white.



VaughnBiceps.jpg Upper Arm Armor
  • Animated style Phase II upper arm armor.
  • Armor is painted matte or satin white with grey detail.
  • Armor is cylindrical with no detail/sculptural features.
  • An approximately 1 inch grey stripe is present down the middle of the outside face of the armor.
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.
  • Armor is weathered with shades of grey.



VaughnElbows.jpg Elbow Armor
  • Animated style Phase II elbow armor.
  • Elbow armor is separate from the forearms.
  • Armor is painted blue.
  • Armor is weathered with shades of grey and has scuff marks.
  • Scuff marks expose the underlying white.




VaughnForearms2.jpg Forearm Armor
  • Animated style Phase II forearm armor.
  • Armor is painted matte or satin white.
  • Right forearm has a compad with six small buttons, one large main button, and one slightly smaller rectangular button.
  • An approximately 1 inch grey strip is present on the top face of the forearms.

An approximately 1 inch blue stripe is present around the wrist of the forearm, approximately ½ inch from the bottom edge.

  • 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 and has scuff marks.
  • Scuff marks expose the underlying white.


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



VaughnHands.jpg Hand Plates
  • Animated style Phase II hand plates.
  • Armor is painted blue.
  • Hand plates are mirror images of each other.
  • Hand plates have a rounded 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 and has scuff marks.
  • Scuff marks expose the underlying white.




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.



VaughnChest.jpg Chest Armor
  • Phase II animated style chest armor with a commander badge.
  • Armor is painted matte or satin white with blue details.
  • Chest armor has a blue stripe detail that begins at the center of the neck and extends down the chest plate to the bottom of the breast.
    • At the bottom of the chest is a symbol consisting of a white square with a horizontal white bar just above it.
  • Lower portion of the chest has a squared notch for the abdomen armor to fit into.
  • Chest and back plate match together at the sides and shoulders with no open gap.
    • Butted seam lines are permitted if required.
  • A command badge on left chest with four indented colored squares and an elongated trapezoid below the squares.
    • Base of plate is a grey.
    • Indented trapezoid is dark grey.
    • Indented squares are orange-blue-dark grey-white starting from the left.
  • White shoulder straps fit into the top of the chest and back.
  • Blue areas are weathered with various scuff marks and fading.
  • Scuff marks expose the underlying white paint.
  • Armor is weathered with shades of grey.



VaughnBack.jpg Back Armor
  • Animated style Phase II back armor.
  • Armor is painted matte or satin white.
  • Back armor has a detail plate consisting of four circles and five horizontal bars.
    • Circles and bars are painted grey.
  • Back and chest armor match together at the sides with no open gap.
    • A seam line is present.
  • Shoulder straps are horizontally ribbed areas that sit slightly lower than back and slightly narrower than adjoining back shoulder area.
    • Straps appear as permanent extensions of the back.
    • Shoulder straps are painted matte or satin white.
  • Armor is weathered with shades of grey.



VaughnPack.jpg Jetpack
  • Jetpack is painted matte or satin white.
  • The center thruster section is painted dark grey.
  • A dark grey detail line runs along the outside of the jetpack.
  • The jetpack is weathered with shades of grey.




VaughnAbdomen.jpg Abdomen Armor
  • Animated style Phase II Abdomen Armor.
  • Armor is painted matte or satin white with light grey overlay.
  • Abdomen armor protrudes out in the front middle to match the shape of the chest armor.
  • Four Inset lines run up the front and spread outward and divide the abdomen into sections.
  • Abdomen armor joins at the rear and is covered by a center plate on the back.
  • Grey areas are weathered and expose underlying white.
  • Armor is weathered with shades of grey.



VaughnCod.jpg Codpiece and Belt Front
  • Phase II animated style cod armor and belt.
  • Armor and Belt are painted matte or satin white.
  • Belt is approx. 3" tall and divided into 1.75" wide segments.
  • Front of belt has a key/slot detail.
  • Belt boxes are mounted at the hips.
  • Cod and Posterior armor are connected at the hips.
  • Butted seams are permitted at this connection if required.
  • Armor is weathered with shades of grey.



VaughnPosterior.jpg Posterior Armor, Belt Rear and Detonator
  • Animated style Phase II posterior armor, belt and detonator.
  • Armor, belt and detonator are painted matte or satin white with a light grey belt.
  • The belt segment directly behind the right belt box is painted orange.
  • Belt is about 3 inch tall and divided into segments.
  • Cod and posterior armor are connected at the hips.
    • Butted seams are permitted at this connection if required.
  • Detonator is centered on the back of the belt with no control buttons.
    • Detonator has two lines that wrap around the tube and are about ½ to ⅝ inches from each end.
    • Line detail may be inset or painted on.
  • Detonator end caps have center area painted grey.
  • Armor is weathered with shades of grey.


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



VaughnBeltboxes.jpg Beltboxes
  • Animated style Phase II belt boxes.
  • Boxes are attached to the belt and centered along each side.
  • Left box is painted light grey.
  • Right box is painted white.
    • Inset detail near the top has an upside down “U” shape.
  • Boxes are weathered with shades of grey and scuff marks.
  • Scuff marks expose the underlying white.




VaughnThighs.jpg Thighs
  • Animated style Phase II Thigh Armor.
  • Armor is painted matte or satin white.
  • Two parallel vertical blue stripes approximately ½ inch wide each and ¾ inch apart run down the center of the outside facing side of each thigh.
  • Front of thigh armor has a flat triangular area near the knee with a notch cut out for the knee armor.
  • A ridge line continues upward from the flat triangle area up to the top edge.
  • Rear of the thigh has an indentation.
  • Armor is seamless.
    • No visible traces of how the armor was assembled are shown.
  • Armor is weathered with shades of grey and has scuff marks.
  • Scuff marks on blue stripes expose the underlying white.



VaughnKnees.jpg Knee Armor
  • Phase II animated style knee armor.
  • Armor is painted matte or satin white.
  • The bottom of the knee armor has a 1" blue stripe that extends from the bottom edge.
  • Two vertical, blue stripes are present on the side of the knee armor that align with the stripes of the thigh and lower leg armor.
  • Knee armor is detached from the lower leg armor.
  • Knee armor sits flush with the front of the lower leg armor.
  • The knee armor is attached to the wearer using black elastic straps, or a similar method.



VaughnShins.jpg Lower Leg Armor
  • Animated style Phase II Lower Leg Armor.
  • Armor is painted matte or satin white.
  • Two parallel, vertical, blue stripes approximately ½ inch wide each and ¾ inch apart run down the center of the outside facing side of each calf.
    • The vertical blue stripes should start approximately 1-2 inches below the top edge of the calf
  • Front of lower leg armor has a triangular detail just below the knee and a hard ridge line that runs down the front of the shin.
  • Back of lower legs have an indentation just under the calf that extends down to the ankle.
  • The outside of the calf is seamless.
    • A clam shell opening on the inner seam is acceptable.
  • Armor is weathered with shades of grey and has scuff marks.
  • Scuff marks on stripes expose the underlying white.


OPTIONAL Level two certification (if applicable):
  • Armor is seamless and has a calf spoon that inserts behind the lower leg indent edge and is secured in place.



TC animated boots.jpg Boots
  • Animated style Clone Boots.
  • Boots are white.
  • Boots are high enough to cover the ankle and leave no visible black under suit.
  • Boots are lace-less and have flat soles that are grey.
  • Boots have a front center strip running from the toe to the front top edge at the ankle.
  • A strap across the top of the foot, and a flat white disc on each side that complete 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.

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