Return of the Dark Lord
October 2007, I set out to make a Darth Vader costume for Halloween that would “wow” people (see Becoming Vader tab). For the most part I hit the mark and even won first place in one of the largest costume contests in Greenville ($100 and a 3 hour limo ride). It was a lot of fun, but the countless hours I spent in the garage (probably nearly 80 hours) landed me in hot water with my better half. She was so relieved when the costume completed the day before Halloween and it was ready to go into a box until next year.....or was it?
A few small parts I needed to complete the fabrication did not arrive until after Halloween, thus prolonging the project. I am not sure exactly when it became an obsession, or rather a sickness, but one thing is for sure, my journey to the Dark Side continues to this day. Every part of the Halloween 2007 costume has been replaced or modified beyond recognition. No doubt I have crossed the line to super-geek status in pursuit of the perfect Vader costume for next Halloween. The kids love it but my wife.......well let’s just say, “The Emperor is not as forgiving as I am.”
2007 Costume
Current Project
Old Mask / Helmet - Heavily modified ABS plastic two tone paint and velcro helmet to mask attachment, no lining, foam padding.
Current Mask / Helmet - Slightly modified Master Replicas fiberglass limited edition (999 of 1000) studio reproduction with interlocking suction helmet to mask attachment, leather lining, and suede padding. High gloss paint.
Old Cod Piece - Cheap vinyl glued to plastic backing
New Cod Piece - Real leather between high density foam with leather backing and cut-outs for the belt boxes. Custom made in Argentina.
Old Belt Boxes - Modified to add metal grill
New Belt Boxes - Further modified by grinding off plastic silver knobs and replacing with real aluminum knobs. Machined in Argentina.
Old Neck Seal - This was actually pretty sweet and fan made in Spain
Neck Seal - High gloss fiberglass seal as an integrated piece to mask like ROTS
Old Suit - Rubies faux leather suit. Very hot ad too shiny. Uncomfortable fit.
New Suit - Custom made by a prop maker in Argentina from 17 different measurements of me . Very high quality, real leather died all the through and quilted liner. Also, added mesh backing and mesh shoulders to release heat where suit is covered by cape. Suit covers neck.
New Shoulder Armor - Fiberglass recast by a fan in the Philippines and modified with think edges. Attached shoulder bells using doll house hinges and marine epoxy. Painted with several coats of automotive high gloss paint.
Old Shoulder Armor - Rubies plastic supreme costume. Very thin edges and silver on black paint.
Old Cape - Rubies supreme costume. Very light weight material cut from ROTS original patterns. Cape in not lined.
New Cape - Custom made for me in Argentina by a fan from heavy Alcapuna material with pleats added to original pattern to give a more ominous and flowing look. Cape is satin lined.
New Saber - Bought a broken Fx light saber on E-Bay, gutted it, added a terminal cap inside to look like a light beam generator.
New Chest Box - Complete redo. Used grinder to remove plastic rocker switches, coin slots, and red / green lights. Replaced with machined aluminum coin slots, real lighted rocker switches, and larger movie accurate red / green light (in correct order). Replaced circuitry to movie accurate blink sequence.
Old Chest Box - Replaced plastic billet mods with machines aluminum