Added Oct 5, 2011
I made several costumes this summer as part of a “Return of the Jedi” group I entered in San Diego Comic Con’s Masquerade. Out of all the costumes in our group, Chewbacca was my favorite; in fact, it’s my favorite creation of all time. While the materials themselves didn’t cost very much, this is the most labor intensive costume I’ve ever made (about 10 -12 hrs a day for 2 weeks just on the jumpsuit; the mask was another day and a half).
The jumpsuit and back half of the mask are made with a medium weight mesh fabric and then synthetic hair is latch hooked row after row after row to create the long shaggy fur. The mask was made of Rigid Wrap, painted and then synthetic hair was carefully hot glued onto the mask. I then hand sewed the back half/hood to the plaster mask and blended the hair accordingly. The pouch is made of faux leather and the pieces on the bandolier were cast in plaster from molds I made based on pictures of the actual bandolier from the movie. Chewie’s feet are made from polar fleece, fake fur and stuffing similar to oversize slippers. The only purchased accessories for this costume are the gloves he’s wearing and Chewie’s bowcaster (not shown in this picture).
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