I made this (F-117 Night Hawk) Stealth Fighter costume for Halloween 08. It took me about 2 weeks to complete, about 3 or 4 hours each night. Materials cost about $120.
It is made off a 62" HDTV cardboard box
Other Materials Include: scuba tank back pack, hot glue, water based latex paint, cardboard tape, some spray paint, 120mm PC cooling fan, EverReady 6 volt battery, 3 volt LEDS red/blue, 3 volt battery's, 6 LED Multi-Sequencer bike light, acoustic foam, car tint, chemical lights.
Believe it or not I measured nothing during this project. I used a aluminum strip to cut strait edges and built it all from my head no drafts or major plans. I just built each piece as I came to that point in the project. I did almost give up several times on this project, but overcame issue like wight, size, and worst of all getting the angles right. It turned out to be very sturdy. It was put to the test at our Halloween party, all the wings where hit several times hard and came back with minimal damage. The cooling fan keep me cool all night and LEDS looked awesome.
The complete picture set can be found at: http://s466.photobucket.com/albums/rr27/gammasignal/Stealth%20Fighter%20Halloween%20Costume/?start=all
Video at: http://www.youtube.com/watch?v=6RXApnyIFMA
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