Revan for eldest's Halloween costume

[hpfan975]

Pretty much a first time poster, go easy on me.

For the past couple of years, I've given the kids a choice: Halloween costume, or Harry Potter Yule Ball (our Holiday Party) costume? I can't do both, so they have to pick.

Last year for the eldest, it was Hiccup from How to Train Your Dragon 2.

The younger was Cloudjumper, Valka's dragon


This year, I wanted him to help so he could start to learn how to make cool stuff (and while I am still way away from the awesome stuff I see on the RPF, I still need some help as the boys see what is possible [thanks, RPF members!:devil). That sent him on lots of research on light saber hilts, mask, etc, while I went straight to the 501st for costume references since I'd never seen the character myself :eek.

We started with some sketches on cover stock

I picked up a yoga mat for <$10 at Marshall's, and went to work. I cut the pieces from yoga mat and covered them with a layer of a large sheet of craft foam. I sandwiched lengths of rope cheap camp poly rope (as seen in the photo below) I had on hand between layers to make the raised sections. Lots of contact cement!

In the photo above, you can see the camo rope (line?) and how it looks when sandwiched between craft foam and yoga mat for the chest plate.

The Mask was the key element, so we spent a fair amount of time on it.
from sketch to finished. Found a snap on motorcycle helmet face shield in smoke, and cut it down with a dremel cut-off wheel for the lens. The rest of the mask is craft foam layers and paint, built up from a paper model. Came out pretty well, I think.
View attachment 549038
Held it in place with some foam scraps and added elastic straps

 

[hpfan975]

Forgot to take into account the extra layers, and when we switched gloves to the ones we had on hand, somehow the vambraces were too tight. Oh well. still looked cool with same sandwich technique foam and rope. Emergency repair needed Halloween night on the hand armor (left) while we sorted out the inside-out pinky finger
(see stitches at right of the glove on left).

 

[hpfan975]

test fitting. The boy built the light saber hilt himself from a paper towel roll and craft foam + a bike bar-end blinky light; hoping to pass on some skills.

 

[hpfan975]

finished costume just before going out Halloween night.
mask detail. Came out pretty well, though I think the silver could use some darkening/dirtying up, but I ran out of time. Layers were spray Plastidip, spray gray, red, and silver; weathering with black craft acrylic, and a spray clear coat from the hardware store.
For some reason, I was inordinately proud of using the zipper foot on the sewing machine to put in the piping on the exercise shirt we bought.
Hood, capelet and cape view. The box pleating on the cape took forever, but it came out okay I guess.
I liked this shot (even if you can see the yoga mat pattern on the chest armor). I used the male part of a snap assembly for the mask "speakers" or whatever they are. Filled with a circle of craft foam and incised some lines. Still need to paint them black.

 

[HeadMan90]

Looks great! I especially love the way the mask turned out. As you said, key element, and you nailed it!