When The Mandalorian first went into production, it wasn’t the massive Disney+ flagship we know today. It had a tighter budget compared to the Star Wars films, and the crew often had to get creative to pull off big scenes. One of the most unexpected challenges came during the filming of the Season 1 finale: they didn’t have enough stormtrooper costumes.
If you remember how Season 1 ends, it all builds up to a tense, high-stakes standoff in the small town on Nevarro. Moff Gideon arrives with overwhelming Imperial forces, pinning down Mando, Cara Dune, and Greef Karga inside a cantina. Outside, a large squad of stormtroopers lines the streets, blasters ready, while Gideon delivers chilling monologues and unleashes the deadly E-Web cannon. It’s one of the most visually striking and suspenseful sequences in the show, packed with tension, firepower, and that classic Star Wars sense of overwhelming odds.
Rather than delay production or rely on CGI, the team reached out to an unlikely source, the 501st Legion, a fan organization known for building screen-accurate Star Wars armor. These dedicated fans weren’t just showing up for fun, they ended up saving the day.
From the episode Disney Gallery / Star Wars: The Mandalorian, where we get to see behind the scenes of The Mandalorian season 1, to find the specific details, you should head to episode 8 of the series.
The 501st Legion, also known as “Vader’s Fist”, is a worldwide organization of Star Wars fans, founded by Albin Johnson and Tom Crews in 1997. These passionate enthusiasts build and wear meticulously crafted costumes, often portraying stormtroopers, clone troopers, and other Imperial soldiers. They’re a common sight at conventions, charity events, and community appearances. But stepping onto the actual set of The Mandalorian? That was something else entirely.
Jon Favreau, the creator of the series, and Taika Waititi, who directed the finale episode, needed a full squad of stormtroopers for the climactic standoff, but the production didn’t have enough suits on hand. Instead of scrambling for a workaround or relying heavily on CGI, Favreau had a brilliant idea: call the 501st.
The 501st already had connections to Lucasfilm, having been recognized over the years for their dedication and attention to detail. So the call went out, and in came a group of real fans… with their own gear. What’s remarkable is that the armor they wore was so authentic, it blended seamlessly with what was already being used on set.
Favreau praised the 501st for their readiness and professionalism:
“So they walk onto our set and they’re right in the middle of the filming of The Mandalorian, which they’d been hearing rumors about, and it was fascinating,” he said. “It looks huge. Fills up our entire set. Looks great. And they know exactly how to act like a stormtrooper.”
Dave Filoni echoed that sentiment in the behind-the-scenes episode: “You direct them, but they know how to move. They know how to stand. They are stormtroopers. They were wonderful. They did a great job.”
Thanks to the 501st Legion of Stormtroopers, we got one of the most intense and unforgettable sequences in The Mandalorian Season 1’s finale. Their presence helped sell just how overwhelming and terrifying the Empire could still be, even in its final days. Without a single word, those fan-made costumes reminded us that the Empire’s shadow hadn’t disappeared just yet.