Costuming:RC grunt

From 501st Legion Databank
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Republic Commando - Grunt
RC Grunt full.jpg
Model RC-10991, Photo by Jessie Akers-Bell


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Description: Republic Commando: Grunt
Prefix: RC
Detachment: Clone Trooper Detachment
Context: Star Wars: Republic Commando (Video game and novels)

Republic Commandos are elite trained soldiers of the Grand Army of the Republic. They are assigned to carry out operations too delicate for standard troopers, such as covert infiltration, sabotage, demolition, and assassination.


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.


RC Grunt helmet.jpg Helmet
  • Katarn-Class Helmet from Star Wars: Republic Commando.
    • Helmet is painted white.
    • Helmet has a matte finish.
  • Blue or black mirrored visor.
  • Frown is painted black.
  • Detail groove lines are painted black to bring out groove lines.
  • Spotlight holder on right ear.
  • Side vents under the ear column include a black large rectangle recess, with four white vertical rectangles on top of that recess.
  • Three cheek vent recesses are present near the ear column.
  • Two front chin aerators are painted black or dark grey.
  • Chin vocoder is painted black.
    • The recess behind the vocoder is black as well.
    • A black painted trapezoidal section goes down from the chin recess towards the neck area.
  • Two bands around back of helmet, top band is black and bottom band is primer grey. The greyband is broken up by the back vent detailing.
  • The rear vent detailing includes four protruding square details between two white rails going vertical along the back of the helmet. The entire area between the white rails is painted primer grey. The grey vertical section ends right before the neckring, leaving a thin white line.
  • Armor is weathered in shades of grey and brown.


OPTIONAL Level two certification (if applicable):
  • Visor is black with blue lighting for visor illumination installed along the upper edge of the visor and concealed behind the helmet edge (EL Wire, LED, and Acrylic Rod are acceptable).
  • Spotlight holder includes a white LED that can be turned on.




CommNeckSeal.png Neck Seal
  • Neck Seal is made of black vinyl or leather type material.
  • Bib covers the entire area within the neckline of the chest/back armor.
  • Ribbed neck section connects to the bib.
  • Bib features twelve trapezoidal details running around circumference of the neck. Trapezoids are longer in the front of the bib, and decrease in size as they run towards the back of the neck.
    • Six trapezoids with recessed rim are present on the front of the bib.
    • Six raised trapezoids are present on the rear of the bib.




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



RC Grunt shoulder.jpg Shoulder Armor
  • Katarn-Class shoulders from Star Wars: Republic Commando.
  • Shoulders are rounded on both ends with a raised center section in between the ends.
    • Shoulders are painted white.
    • Shoulders have a matte finish.
  • The central raised band has diagonal grooves starting farther away, and starting to go towards the center reaching the bottom end of the raised band.
  • Recess in center of shoulder bell with embedded buckle detail.
    • Buckle is dark grey.
  • Armor is weathered in shades of grey and brown.
    • Groove lines are darkened with black, dark gray or weathering.



RC Grunt biceps.jpg Upper Arm Armor
  • Katarn-Class biceps from Star Wars: Republic Commando.
    • Biceps are painted white.
    • Biceps have a matte finish.
  • Biceps have a sharp shield-shaped recess on the other sides, with the long flat edge on top, tapering down ⅔ of the way, and then sharply turning in to a point.
    • Triangular recess is painted black.
  • Biceps are seamless.
  • Bottom of biceps on each side have two “tooth” details.
    • The shorter tooth should be towards the front (bicep), and the longer tooth in the rear (tricep).
  • Armor is weathered in shades of grey and brown.



RC Grunt elbows.jpg Elbow Armor
  • Katarn-Class elbows from Star Wars: Republic Commando.
    • Elbows are painted white.
    • Elbows have a matte finish.
  • Elbows are attached or hinged to gauntlets.
  • The elbows have a white band going around the elbow-pit.
  • Armor and strap is weathered in shades of grey and brown.




RC Grunt forearms.jpg Forearm Armor
  • Katarn-Class forearms from Star Wars: Republic Commando.
    • Forearms are painted white.
    • Forearms have a matte finish.
  • Forearms have raised detail on top and curving indented designs. The side with double curved indents goes on outside of forearm.
  • On the raised wrist-area band, there are two square details with recessed edges. These squares are painted dark grey.
    • Wrist area features two evenly spaced grooves going around the circumference of the wrist area.
    • Between the grooves and square raised details there are two dark grey dots in line with groove details.
  • Forearms are seamless.
  • Forearms have attached or hinged elbows.
  • Armor is weathered in shades of grey and brown.




RC Grunt hands.jpg Hand Plates
  • Katarn-Class handplates from Star Wars: Republic Commando.
    • Handplates are painted white.
    • Handplates have a matte finish.
  • Handplate return edge is longer on the side closer to the thumb than the return edge near the pinky finger.
  • Right handplate specific detailing:
    • Handplate has an elevated horizontal bar on top of the handplate.
  • Left handplate specific detailing:
    • Handplate has an elevated rounded “T” shape with edge indentation.
    • Long vertical groove with a primer grey greeblie along the top of the groove.
    • Two small hemispheres near bottom of handplate, split by T shape.


OPTIONAL Level two certification (if applicable):
  • Vibroblade attachment on left hand.
    • Vibroblade attachment is painted silver, with a gunmetal edge.
    • Core of vibroblade is a rounded rectangular black recess, with a cylindrical blue center.
    • Core blue cylinder lights up.




CommGlovesISO.png Gloves
  • Black gauntlet style gloves made of leather, nylon, or other low pile fabrics. Gloves cover the wrist area.
  • Gloves do not have any labels or logos visible once armor is attached.
  • Gloves have embedded armor padding along fingers and back of hand.



RC Grunt chest.jpg Chest Armor
  • Katarn-Class chest armor from Star Wars: Republic Commando.
    • Chest is painted white.
    • Chest has matte finish.
  • Armor has an elevated “V” shape front with elevated chest area.
  • Chest and back armor match together at the sides with a slight open gap.
  • Shoulder area is seamless.
  • Armor is weathered in shades of grey and brown.



RC Grunt back.jpg Back Armor
  • Katarn-Class back armor from Star Wars: Republic Commando.
    • Back is painted white.
    • Back has matte finish.
  • Backplate is flat on back and aligns with backpack.
  • Back has a matte finish.
  • Bottom of back includes a recessed bottom, with a slight curve along most of the bottom of the backplate.
  • Chest and back armor match together at the sides with a slight open gap.
  • Armor is weathered in shades of grey and brown.



RC Grunt backpack.jpg Backpack
  • Katarn-Class backpack from Star Wars: Republic Commando.
    • Backpack is painted white.
    • Backpack has matte finish.
  • Backpack attaches to back armor without visible hardware.
  • Backpack includes a small grey circle painted on the left side with no dimension, lying on the sides near the back of the backpack.
  • A raised detail panel is present on the left side of the center portion of the backpack, panel rim is painted dark grey.
    • Panel recess is black, with blue illuminated details
    • Detail panel has two recessed sections.
      • Left side of panel has a recess shaped like a square on the top, trapezoid below it with a smaller square below that. The larger upper square has a two digit ID number. ID number may be any two digit combination as RC ID numbers are based on four digits, but only show the last two.
      • Right side of panel has rectangular recess with the following lighted detail sections: Upper square, left side lighted rectangle, and three right side small lit rectangles next to the long left rectangle light.
  • There is a recessed trapezoidal detail in the lower right of the center portion of the backpack.
  • There is a small primer grey circle above the recessed trapezoidal detail on the back of the backpack.
  • The bottom section of the backpack includes two handles.
  • Backpack construction shall have no visible seams.
  • Armor is weathered in shades of grey and brown.



RC Grunt abs.jpg Abdomen and Cod Armor
  • Katarn-Class abdomen armor from Star Wars: Republic Commando.
    • Abdomen armor is painted white with light grey details.
    • Abdomen armor has matte finish.
  • Armor has a connected cod and abdominal piece with surface 3-dimentional details and a permanent belt box waist attached on the sides.
    • Side belt boxes include a front detailing, including two black rectangles stacked vertically atop each other, with no dimension.
  • The abdominal area includes four raised details, two on the far sides being squares and the center two being a similar shape but conforming to the bottom of the chestplate.
    • Groove between central abdominal trapezoids is painted light grey.
  • On either side of this ab detailing includes raised door hook details, with the hook facing down.
  • Top section of abdominal plate besides hook details and central two abdominal trapezoids is painted light grey.
  • Cod includes raised detailing and grooves.
  • Abdominal plate attack to the lower back and posterior armor with a visible closed seam.
  • Armor is weathered in shades of grey and brown.



RC Grunt posterior.jpg Kidney and Posterior Armor
  • Katarn-Class posterior armor is a solid butt and back piece with protruding rectangle and angled edge butt detail.
    • Posterior armor is painted white.
    • Kidney armor is painted light grey.
    • Posterior and Kidney armor has matte finish.
  • On the sides of the posterior armor, a groove forms a triangle detail.
  • Permanent belt box waist aligns with Abdominal armor.
    • Side belt boxes include a front detailing, including two black rectangles stacked vertically atop each other, with no dimension.
  • Armor is weathered in shades of grey and brown.



RC Grunt thighs.jpg Thigh Armor
  • Katarn-Class thigh armor from Star Wars: Republic Commando.
    • Thighs are painted white.
    • Thighs have a matte finish.
  • Has arching indent in back and raised ridge in front, flaring out when reaching the knee.
  • Thighs are seamless.
  • Armor is weathered in shades of grey and brown.



RC Grunt shins.jpg Knee and Lower Leg Armor
  • Katarn-Class knees and shins from Star Wars: Republic Commando.
    • Knee and shin armor is painted white.
    • Knee and shin armor have matte finish.
  • Shins are rounded at the calf.
  • Rear of shins have a vertical raised ridge going from the top edge to halfway down. At the bottom of the ridge, on either side there is an indented rounded trapezoidal detail that goes halfway up the ridge.
  • Knees have a rounded shield pattern with two vertical indents running from top to lower half.
  • Shins are seamless or constructed with hidden closures.
    • Rear or inside leg seams are acceptable.
    • Front seam may also be overlapped with indented edge to provide appearance of seamless edge.
  • Knees are hinged to top of shins.
    • Angle of knee follows alignment of front leg surface.
  • Armor is weathered in shades of grey and brown.



RC Grunt shoes.jpg Boots
  • Katarn-Class boots from Star Wars: Republic Commando.
    • Boots are similar to regular grunt clone boots.
  • White, ankle high or tall enough to cover the ankle and eliminate any black undersuit visible at the ankle.
  • Boots are lace-less.
  • The boots have armor detail to include a natural seam at the toe and a strap that goes over the top of the foot with two protruding disks at each side of the strap.
    • Shoe disks are flat.
  • There are no markings or labels from the shoe makers.
  • Boot soles have a treaded bottom.
    • Boot soles are painted black or primer grey.
  • Boots are weathered in shades of grey and brown.



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.



CommDC17ISO.png DC-17m (Assault Rifle Configuration)
  • Base weapon has bulky design accurate to the game with the following characteristics:
    • Enclosed trigger guard.
    • Elongated front grip under forward compartment.
    • Back angled stock cover with louvered design.
    • Shield flap on left side, located above trigger handle.
    • Multiple sights on top edge.
  • Sections of the blaster are painted aluminum or black matching visual references.
  • The DC-17m can come in multiple forms, these details pertain to the Assault Rifle configuration:
    • Barrel attachment is present on front of blaster.
      • End of barrel has a patina-like finish.
    • Standard DC-17m magazine type.
    • Blast door is in the closed position.


OPTIONAL Level two certification (if applicable):
  • Blue lighted 3 digit numeric display counter (max count 300).
  • Blue LED light bars on magazine.
  • Blue LED on top cylindrical detail, in front of rear sight.






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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