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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).