I finished the overalls this weekend. I could not find an accurate colored corduroy in the correct wale, so I custom dyed it. The screen-used cord was about 16 wale and was medium blue. Corduroy is very difficult to color match because it photographs very differently depending on the lighting conditions. The velvet fibers catch the light and make it seem much lighter than it really is. That's why the overalls in the movie look light at times, and other times very dark.
http://www.ryannagata.com/files/gimgs/32_colortest.jpg
I also could be wrong about this, but the overalls in CP1 looked darker than the ones in CP2. I opted for the slightly darker look as I think it looks better.
I ended up purchasing a 16 wale corduroy that was sort of a light blue/aqua. I tinted 2 yards of it in my washing machine with 1 bottle of RITT Royal Blue and 1/2 cup RITT Fuchsia. That formula gave me an appropriate sky blue shade and helped neutralize the green in the fabric a little bit.
I applied the plastisol transfers with my heat press and they worked perfectly! Corduroy is very textured, so I was afraid they might not apply very well, but they ended up going on without a hitch:
http://www.ryannagata.com/files/gimgs/32_corduroypress.jpg
I didn't bother documenting the sewing process since I covered that pretty well with the development of the pattern. Here are the overalls finished. I consider this a prototype. I'm going to make some slight adjustments to the pattern on my next set. I think the overall straps should be about 1/4" thinner:
http://www.ryannagata.com/files/gimgs/32_overalls2.jpg
I shortened the red collar on the shirt a little. It was too high (you can still see the original collar height in the last picture of this thread since I took that picture earlier)
http://www.ryannagata.com/files/gimgs/32_wannaplay2.jpg
The wig is temporary because I finally received my samples from the good folks at National Fiber Tech!!! This is the same company that made the wigs for the original Chucky dolls:
http://www.ryannagata.com/files/gimgs/32_nft.jpg
This is the same modacrylic fiber that his hair was originally made from and it has a very unique texture. It's very straight, but has lots of volume like Chucky's original hair. All the wigs I found are silky, meant to simulate human hair, so they lay much flatter. I'm very happy with this little discovery because the texture and color are perfect--the last piece of the puzzle:
http://www.ryannagata.com/files/gimgs/32_accuratehair.jpg