Kylo Ren – Sleeve Rebuild, Pleats, Continued

Finishing The Pleats…

Finishing the other sleeve…

Almost done with the other sleeve…

Other sleeve finally finished!

I got the sleeve pleats all completed by Halloween, but I just didn’t have enough time to get them fitted and added to the base shirt. Rather than rush it, I chose to just wear the Rubie’s again.

Kylo Ren – Sleeve Rebuild, Pleats, Continued

Still Creating The Pleats…

Lots and lots of pleating…

The paper “template” was working, but it wasn’t very efficient because it wasted valuable time having to basically create the pleats in paper, and then do them again with the fabric. So, I switched over to just placing a small piece of white duct tape on each pleat, and then used the proper colored marker to designate the pleat size on the chart. This makes things go a lot faster. I now have the first sleeve completely pleated.

Kylo Ren – Sleeve Rebuild, Pleats, Continued

Still Creating The Pleats…

Lots and lots of pleating…

Starting point for this pleating session…

Progress after about 5 hours of pleating…

The further I get into the sleeve, the harder it is to keep up with where I am on the pleating chart. So, I have created a paper “template” to try and keep things more organized.

Close up of the template with the pleats.

Kylo Ren – Sleeve Rebuild, Pleats, Continued

Creating The Pleats…

Let’s get to pleating…

The fabric laid out, ready to start…

Starting at the end of the sleeve, I first made the hem. To help make this a bit easier, I used Heat Bond to create a nice firm base to work from.

Hem folded over and pinned.

Hem, ironed to activate the Heat Bond.

Beginning the pleats…

Kylo Ren – Sleeve Rebuild, Pleats

Time For Pleats…

Since Halloween is quickly approaching, I decided to take a small break from Boba Fett and give Kylo Ren a little attention.

After a lot of research, I decided upon some fabric to use for the pleated sleeves. Let’s get to pleating…

I bought this black duck cloth from Walmart.

I found this guide (by robo3678) for the various pleat sizes.

Close up of the fabric’s weave…

Kylo Ren – Sleeve Rebuild

Preparing For The Pleats…

Since the Rubies deluxe costume is FAR from deluxe, I’m going to start working on replacing it will better parts.

I wore this black jersey shirt under the Rubies costume to try and “beef up” the sleeves a bit. My plan is to remove the sleeves and then attach the new, pleated sleeves to the main part of the shirt.

I pinned the sleeve up a bit to take out some of the slack.

Marking the point on the main shirt where the seam lines up…

Area clearly marked. I repeated the same process on the other side…

I then used a seam ripper to separate the sleeves from the main part of the shirt.

Kylo Ren

A Change Of Pace…

After wearing the Anakin Skywalker costume a few years, I decided I wanted something a little more menacing this year:

I already had the Black Series helmet, and the Black Series light saber, so I just bought the Rubies deluxe costume, and bought a new belt, gloves and boots. I then sewed up a better hood and scarf. It worked for Halloween, this year, but will need massive improvements for next year.

I plan to just start replacing the main soft costume parts with better parts, taking my time to get them really accurate.