costume construction
Working from resources from the internet, I reconstructed the costume from a fabric that closely resembled Khan’s original outfit. The images below illustrate the progression of the jacket base and puffy elements.
Weathering the fabric
Once the major parts have been sorted out and constructed, I applied paints and dyes to age the elements and fabric, making it more worn and gritty in appearance. The process is slow, and takes layers and layers of application to achieve a look that is readable from a distance but not over done. This attention to detail makes the costume more accurate to the character’s look and environment, helping to tell the story visually.
Accessories
Using leather, a 3D printer, electric wire, and some paint, I was able to piece together more detailed accents to make the costume more accurate. Displayed here are the wrist communicator, the belt, and wire necklace.
I worked with Alexi Bustamante, who created the metal belt elements and wrist communicator inset pieces. He used 3D modeling software and printed them for me. I retouched the plastic print with acrylic paint to finish the look of the belt buckle and wrist communicator insets.
Jasmine, of Working Dogs and Sons, took my belt backing pattern (reminiscent of a tabi sock shape) and made the leather belt and belt buckle base. I think it turned out awesome! Check out her online store, her work is gorgeous!
Final Product
Now that the elements have come together, the costume is complete! The final costume consists of a custom made jacket, bra cover, pants, belt, necklace, wrist and ankle bracelet. The final costume was finished in July, just in time for San Diego Comic Con 2022. I think Russell slayed, and made it such a fun and unique cosplay.
