I am an avid fan of the Legend of Zelda Majora's mask. Last year I decided to do around as the skull kid. This build shoes my process, unfortunately i was in a time crunch with school and other things going on so i was bad about taking a lot of pics. This was my first foray into the world of sewing machine working, and although it turned out ok it was quite the learning experience.
Step 1: Head
The head, being the most important part, was what i spent a majority of my time working on. It was constructed from a 14inch acrylic sphere that i covered in Smooth-On Free Form AIR Lightweight Epoxy Putty. Using real tree bark I stamped in the wood texture.
Step 2: Main Suit
As i mentioned this was my first real sewing work, so for the shirt and pants I used an existing shirt and pants as templates to make the patterns that i sewed together. In retrospect i should have gotten better patterns because the ones i made worked, but the fit kinda weird.
Step 3: Fingers
The hands were probably the most difficult part of the costume because i wanted to have full articulation while maintaining the I am made of wood look. I accomplished this by sculpting each piece for one hand then casting multiples. After some dremeling and cleanup i glued them to a cheap glove which i them sewed onto the actual costume glove.
Step 4: Hat
The hat was simple since it was just for show. All i did was take a straw hat add height with a rolled up piece of paper and then cover the whole thing in the costume fabric.
Step 5: Shoes
The shoes like the hat were simple faux coverage. I took an old pair of converse and, using craft foam, made the desired shape of the shoe. Which i then covered in the same costume fabric. With the addition of the rings and some pleather the shoes were both comfy and looked good.
Step 6: Final Details
Final details were added including the neck piece which was sewn from extra green fabric, and spraying all the fabric pieces with brown spray paint to age/ dirty them. Other than that i made two little eyes that i saw out of which worked... ok, but i'm working on revamping the costume including finding a better way to see.
If you decided to make your own the final step would be to go out and have fun with it!
Me dancing in it: