<div class='quotetop'>(GeneralMayhem @ Jun 3 2006, 05:01 PM) [snapback]1255614[/snapback]</div>
I'm curious about this as well.
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Ok. My wife made me a leather Vader Suit. Its a little easier than you think. But it is a LOT of work.
You'll need 3 or 4 Half hides of HIGH quality leather. High quality to avoid numerous flaws and holes in the hide.
You need patterns. Patterns are easy. Go to a sewing type store (Jo-anne fabrics for example) and browse the patterns. You want to find a straight-leg pant pattern, and a simple shirt. Go for a size or two BIGGER than you need to account for shrinkage during the quilting. Remember, its easier to take in, than to let out.
The patterns will need a minimum of alterations. You don't need pockets, but remember that your shirt will button/zip at the rear. The back of the shirt doesn't have to be leather. No-one sees it, after all.
We used a cotton lining for the suit, as well as a slightly thick cotton batting for the quilting, to help the 'ridges' stand out. (It gets VERY hot though). If you are going to use a sewing machine GET A WALKING FOOT. You will need one to avoid the leather slipping. Remember, you'll have three layers of fabric.
The quilting is roughly 1" apart. You can get fancy and do V-hsaped and the like, but thats a LOT more work.
Here is what my suit looks like.
'The only thing I would have done different, is make the tunic a little looser.
Any more questions, feel free to ask.