All the first prop pics lost to water damage but here's the 1999 Vader, and his pals, all homemade, for our band Grand Moff Tarkin:
http://www.geocities.com/dex1138/swmusic_gmt.html
The first Stormtrooper was made out of Bathmats and Milk Jugs because Mike Glover had screwed us. Sure they aren't that correct, but we had to play an hour of Punk Rock in them. All the sets and guns are made from Gatorade bottles and we had a functioning Sarlaac and an Exploding Death Star. Tons of Pyro, this was before Great White. Had some great shows with GWAR and The Misfits.
I think the most fun to make were the Dancing Girls costumes:
The Death Star Stewardesses where my favorite.
Laffo.