One of the full-faced hockey goalie's mask might fit what you are looking for. I'd look at discount sporting goods stores/sites, see if you can find something that might be close in design that will fit your budget.
According to what I've read where her description of the costume goes, the dress is made around a heavy duty corset to get the exaggeratedly small waist. It also has a couple pushup-style bras sewn into it which probably furthers the waist-size illusion as well as giving her a very ample bosom.
Re: SDCC 2013 - first-timer
SDCC is rather family orientated now so your 12 year old should be alright to go. All the vendors have to adhere to strict rules so his accidentally glimpsing material of an adult nature shouldn't be a problem.
Sadly, when I was going I was local so don't know...
Perhaps you could use a pair of glasses frames that fit your face will and use that as a start for a mold. Then you could possibly build off of it, making it more molded to your face once you got a good frame to work with.
I played since about three months or so after it went live up until recently when TOR went live. My toons are primarily on Terenas - Leate, my NE hunter and Twylyte, my NE druid, both 85s. I'll probably get back into it a bit more in awhile but for now TOR has me in its deathgrip. :)
Re: The Force Unleashed II - General Rahm Kota WIP
This is one awesome build. This level of quality both inspires and intimidates me to no ends. :D I can not wait to see the end results along with everyone else.
I do have one question and I apologize if it had been asked/answered before now...
Another cheap option is to use metal coat hangars (Mommy Dearest would be displeased!) for the wire, this being what an SCA friend of my husband's and mine suggested Downside to it is that it will oxidize fairly quickly but is good for a few wears as well as good for practice so you can save...
The Endor scenes were shot in the Redwood Forest in Northern California, not too far from where I grew up as a kid. :)
ETA: Thanks for sharing these pictures!