Here's a General Grievous Costume I built with my son for Halloween '08.

The basic construction is a black pullover from an old cheap store-bought halloween costume, and foam-core assemblies attached with velcro. There's a PVC 'backpack' that has mechanical arms with elastic bands that can flip up giving the General an extra pair of arms.

Step 1: Foam Core Assemblies

This costume was built by eye so you need a decent picture to start from.

The foam core assemblies are sized for a child, but of course could be made larger for an adult. They are cut from paper patterns and most are bilaterally symmetric. Some sections are pre-painted and 'weathered' with dilute black tempera paint to give shadowed 3D effect. I used hot-glue to assemble them, but other glues are fine. When dry, they are aligned onto the body-suit with velcro on the assembly and the suit. The suit velcro should be sewed on (or stapled if you're hasty).
Ok, I'm almost there with the back pack, but I can't quite figure out the arms spring thing. Can you give me a little more direction?? The guys at Ace Hardware are psyched and telling me I'll be the Mom of the Year if I can pull it off. Please.....
are you happy ?
BAD ASSNESS extreme that is freakin awsome<br />
OMGosh!! This is awesome!! My son would be so excited if we could make this...we will definitely try. Thanks for sharing.
Excellent job, exactly what I was looking for.
That's a really cool project... I sure wish i could do that, congrats...
hmmm... i dont like it...
Sweet and i love the cute little laugh at the end by the kiddo in the costume :D 5 stars
hmm....lol seeing all that pvc in there makes me think that haveing a inbuilt PNUEMATIC CANNON would be cool. "haha u may have a light sabre, BUT I have a light sabre AND A PNUEMATIC CANNON, touche' " hehehe
Nice job! Still don't get the arm part :P
woo dud.. great costume.
That's incredible! I'm hoping you've made other costumes/ you're going to make more. I hope you can post them as Instructables! Thanks for sharing! +5/5 stars.
Thanks GorillazMiko, it was fun to make. I've put some of my other work in instructables:<br/><br/><a rel="nofollow" href="http://www.instructables.com/id/GodzillaT-Rex-Costume/">Godzilla / T-Rex</a><br/><a rel="nofollow" href="http://www.instructables.com/id/Quick-PVC-Halloween-Mannequin/">PVC Mannequin</a><br/><a rel="nofollow" href="http://www.instructables.com/id/General_Grievous_Costume/">General Grievous with Mechanical Arms</a><br/><br/>And also in my blog <a rel="nofollow" href="http://www.creatrope.com">creatrope</a>.<br/>
Super costume! My son was Darth Vader last year, and a clone trooper (or "chroopr" as he spells it) this year. I have a strong suspicion that this will be next year's costume. I don't dare show him these pictures until Nov. 1st, or he will want me to make it for him in the next hour and a half.
This is really really cool man, congratulations :-)

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