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REBEL FLEET TROOPER
Here's my stab at the Rebel Fleer Trooper costume.  A big thanks goes to Studio Creations for posting their "how to" which got me started.  I'm going to try not to restate what they've already posted, but instead add some of the things I learned along the way, as well as some screen captures.

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The Helmet

The helmet was vacuformed from a World War II Navy Mark II Helmet, also known as the Talker Helmet.  The RFT helmet uses the Mk. II as the base, and was covered in the back with what appears to be a custom made "scoop".  

The left side of the helmet includes a communications module.  The piece can clearly be seen to include two bumps and a washer/disk type shape, but I haven't seen any detailed pictures of the piece to determine if there are other details not seen in the screen captures, or limited reference pictures.  However, the comm module is very similar to the module included on the Death Star Gunner's helmet, and the DSG's helmet is on display as part of the Magic of Myth (and at Celebration II).  If the piece is the same as the RFT's (which seems likely), then the RFT's comm module may also include three to four vertical lines behind the bumps and disk.

Lastly, the front includes a piece that looks like it was intended to mimic a visor or blast shield.  This piece looks like a black piece with a white stripe along the bottom, but is actually two pieces (see the second pic).  The black piece appears to be a tinted or smoked plastic.  There are also some helmets that can be seen without the dark visor portion, and some that appear to have either larger dark visors, or they were attached in a lower position (see the third pic).  

An interesting note on the visor, is that it appears that Lucasfilm intended this to be a working visor.  The best evidence of this is the ceremonial scene in ANH where several Honor Guards and some RFT are seen with black visors covering their faces (see pics on second row).  Based on the screen captures, I don't think the visor was able to slide down into position, but who knows?  Maybe it was removed and reattached.

When I made my helmet, I started with two pulls of the Mk. II helmet.  The first pull was used as the base for the helmet, and the second was used to cut out the visor piece.  I used a white visor and painted the dark portion with gloss black paint to keep the construction simple, but if you're an accuracy nut you'll need a two piece helmet.  The scoop and the comm module were both custom made. 

Incidentally, this helmet is the same one used by the Rebel Honor Guard

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Some detail can be seen of the comm module here

This pic clearly shows the two piece visor

Composite image showing visor variations

DSG helmet with similar comm module.  Note 3 lines.
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RFT with visor in
the down position

RFT in back row with
visor in the down position

RFT are seen extensively
on Yavin Base

Honor Guard with visor
in the down position
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The Vest

My vest was made from a US military BDU shirt/jacket.  These can be found at most Army/Navy stores, and many online military suppliers.  The best price I have found is at Omaha's, Sportsman's Guide, IMS Plus, and Vermont Army/Navy.  I've never dealt with the last two, but I have shopped Omaha's.  It's one of the best military suppliers around!  Sportsman's Guide is also a reliable dealer.  

The BDU vest is not a perfect match, but the length and fit looks very accurate.  To be more accurate you would need to change the breast pockets and add a row of pockets along the bottom of the vest (see fourth picture).  The third and fourth pictures are from production pictures that show these pockets.  Also, the Rebel Fleet Trooper figure recently produced by Hasbro shows a row of 4 pockets on each side of the front of the vest.  Rumor has it that Hasbro tries not to scratch create these types of details, so Lucasfilm might have provided some reference photos we haven't seen.  

     

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The Pants

The pants are anybody's guess, but they appear to be BDU pants with large cargo pockets on both thighs.  The pockets on the screen used pants appear to have a lot of "billow" to them (see the third picture).  I don't think the current BDU matches these because they have a 3 crease blouse pocket, but they still look close.  Best part is that the BDU pants come in a color called SWAT Grey that you can get at Army Navy stores or online (Omaha's (recommended), Sportsman's Guide, IMS Plus, and Vermont Army/Navy).  

     

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The Shirt

Like the pants, the shirt is anybody's guess.  It is a light blue or blue-gray color, and has some type of bib or flap across the front.  This was probably made for the shoot to hide the buttons down the front of the shirt (see third and fourth pic).  Regardless, any light blue long sleeve shirt will do.  The shirt I used was a Dickies brand work shirt.  Wal-Mart or Kmart probably also has some work type shirts that will fit the bill.

Most rebels don't bother with the bib, but I recommend it as it makes the costume look more accurate, and less like you're wearing street clothes.  If you use the snap system recommended by Studio Creations to attach the bib, I recommend also adding a snap along the top of the bib under each collar tab (so that the snap is hidden by the collar tabs as shown in the second pic below).  This will help to keep the bib from sagging along the top, which will stop it from revealing the top button of the shirt.

     

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The Boots

The general consensus on the boots is that they're WWII German Jackboots, with a straight cut across the top and a rounded toe.  Sportsman's Guide often has East German surplus jackboots that are a close match (pics of mine below).  The only problem is that they are often out of stock.  These boots have a pebble finish, which is likely not 100% accurate, but this is a pretty minor and insignificant detail in my opinion. 

An alternative is a motorcycle style boot.  You have two options.  One is a harness boot, while the other is the conductor boot.  The harness boot has a harness assembly (which will need to be removed), and a square toe.  The conductor boot is much closer, but usually has a buckle at the top of the boot on the outside (which you could remove).  

There are also some black work boots that are close, but these are hit and miss, and are usually not completely flat across the top.  Try Wal-Mart or a western store.  

     

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The Belt

Like the rest of the costume, the belt is straight-forward.  It is a 2 inch wide leather belt with a belt buckle.  The buckle can be seen in both rectangular and octagonal shapes as shown in third and fourth pictures.  Tandy Leather has everything you need to make this yourself, including a 2 inch belt blank, a square buckle blank, and one bottle of brown dye.  To make the belt, you'll need a punch for the buckle holes.  Also, if you buy the belt blank without the snaps, you'll need snaps and a snap setter.  

Most of the movie belts also include a holster for the DH-17 blaster.  I haven't made a holster yet, but I plan on modeling it on the stormtrooper holster since it's a straight-forward design.  Some hardware stores also have drill holsters that work well and look good if you're not an accuracy nut.  

     

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The Blaster

The Rebel Fleer Troopers are seen using and carrying the DH-17 blaster.  This blaster uses a Sterling machine gun as its base with a Singlepoint scope.  If you're looking to make this blaster and the scope, I suggest checking out the PVC Blaster Builders Club for a tutorial.

     

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Screen Captures

       

       

       

       

       

       

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