Actually, and this may just be a pipe dream.............but someone casually mentioned to me some time back that they knew another individual that was going to release some super duper accurate patterns for sale...........of all sorts of Vader and other costume patterns and that the information came from a reliable source.
I have absolutely no idea what they are referring to and am quite skeptical as always.........but it would be a cool notion to ponder. It would rock if it actually came true and had substance. It would have saved me 10 years of research that incidentally keeps going and going and going. You can learn a new detail about your favorite costume once daily if you spend enough time pouring over photos and books.
Several people out there have patterns of their costumes...........some are more accurate than others.......but those folks don't intend to let their patterns go as they are making the costume parts themselves............would be a bit silly to be honest. However, if someone is brainy enough to actually assemble and sew one of these vader costumes themselves.................they are brainy enough to create their own patterns.
For those of you with the desire to create by hand rather than hire it out...............try this:
Take a 12" Vader doll. Take some paper towels and tape together a pattern that fits your tiny mannequin. Make it nice and full like the film suits etc....
Now scale it up 6X .........and divide the parts into sections that will fit fabric that is either 45" wide or 60" wide depending on availability. Don't forget to add 1/2-1 inch to every single edge of each piece to allow for a seam.
Now sew it up and create your masterpiece.
For me it's quite difficult, but not impossible. Most of your local seamstresses can help you do this pattern making if you show them what you strive for...........give them a basic idea of what the piece looks like all laid out flat.............and how tall and wide you are..........they are pretty smart folks if they do this for a living. Not only that, but they can do all the assembly and finishing if you grow tired of messing it up yourself.
Good luck...
Dave