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Need help finding easy materials for Pyramid Head (Silent Hill 2/Movie) costume!

I know there are a few topics and instructables on how to make a Pyramid Head costume already, but mine's going to be a bit different. I'm going to sort of be mixing costume styles of the Pyramid Heads from the Silent Hill movie, and the second Silent Hill game where he made his debut.

I have past experience with this costume, actually. In fact, it was the first costume I ever made myself.

My mom and I originally made the helmet out of posterboard and duck tape, but it didn't hold up so well after a while, plus it had a problem where it would get somewhat lopsided, or if I turned my head, the helmet would stay in place. This is because there was nothing inside the helmet to support my head when I turned it, or to keep it to where it moved and stayed upright with my head.

The robes I made out of a bloody labcoat/doctor's coat with ripped off sleeves, and a bloodied cook's apron. draped over it to conceal the buttons. Made it look kind of odd with the layering, but I worked with it. I used a pair of white female dress gloves with it, because they looked alot like his.

Anyway, this year I was wanting to revamp the costume, and add in a bit more detail, change the style a little. I was wanting to make his helmet more like the Movieverse's helmet', with the sharper angle, and grating on the sides. But I wanted to keep the apron that he had from the second game, since I don't really have the figure for the really ripped PH from the movie.

So I come to you all for help. :) I need suggestions for this. 

I'm also working on a bit of a budget, and I'm not at all good at woodworking. So I can't use anything like fiberglass or actual metal, I don't believe. I want it to look good, look pretty authentic and recognizable, something people could come up to in conventions and say " Dude, that's awesome", but with easy to find and work with materials. I've never sewn in my life, either, so that's out.

My first one I'd like is for his helmet. I already have a decent idea of how to make it. This time I'll probably be working with super glue instead of duck tape this year. Duck tape's a miracle tool, but there's only so far it can go in certain rare situations. Something like a helmet the size of a small child requires a certain amount more work.

For the helmet, I'm probably going to be using window mesh like the kind used in certain windows or porch doors for the grating on the sides of the helmet. I got that as a suggestion from another instructable, and after a bit of testing how well I can see through it, I think I can work with it. I think assembling it will be easy. I may tape it together first just to see what it'd look like fully constructed before I glue it, though.

My main issue with the helmet will probably be support. I need to be able to turn my head, have it move with me and my body when I'm turning around and navigating certain areas. Does anyone have any suggestions on a way to make it do that? Again, it can't be incredibly expensive. ( About more than 20-25 dollars in this case scenario.)

A second bit of help I'd need is his skin. Now, my skin's naturally very pale, but there's the problem of hair. I could try applying some kind of makeup to it, but I imagine it'd smudge badly by the end of the day. If I did that, I'd probably have to wax my arms first. x.x The problem with that is that people would probably want to hug me throughout the day, and I'd be smudging makeup on their clothes.

Another idea I had was trying to find a white leotard or something similarly tight-but-thin to use as his skin. I'd be able to dirty it up a bit to make it look like his.
Only problem is, I don't know where to get one.
There aren't any specialty stores around in a fifteen mile radius that I know of that would sell them, and I can't order online for specific reasons. Does anyone know of any widely known store that would possibly sell leotards, or something similar that I could use to cover my upper and lower body? I know white hose or thin white stockings would work for his legs, but it's the arms and upper body that are bugging me.

The last bit of help I'd need is for the Great Knife, his BFS. I think I'll also be making it out of thick posterboard, possibly layered with cardboard as well, painted silver. But I wanted to know if there's a better way. I made a really ramshackle Great Knife before out of posterboard, but in retrospect, it resembled more of a giant paddle. XP It's not much diffirent from a buster sword, but most of the Buster Sword instructables I see here are only with wood. And again, horrible at woodwork. 
For the handle of the blade, I was probably going to use the handle of a paintbrush or large cleaver. Anything better you all would suggest?


Sorry this is such a long read, but I desperately need the help, and I wanted to get a head start on it before October (the date of the next convention in east TN, I think. And Halloween. ). Thank you in advance to anyone who can offer suggestions. Again, I'm working on a bit of a budget, though. The most I can spend per item is about 20-25 dollars. Shameful as it is to say, I normally get most of my material for costumes from thrift stores, surplus stores, and flea markets. I feel bad that I can't sew or do woodwork like the awesome cosplayers and craftsmen on the site.

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