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NiGHTSintoDreams.Com
The skeleton is made of nylon Plasticanvas sewn together with string, first I started off with crochetting thread, then I ran out and switched to a very thin twine. It took me four tries to figure out a pattern for the helmet part, I was originally planning on melting a sheet into shape but had too many temperature issues with the oven and steaming, and my heat-gun isn't working, so I went the old fashioned rout and just pieced it together. It ended up looking kind of Tron before i put the horns on. The horns were actually a lot easier because they're structure is pretty much exactly the way I built them in Blender when I was making a model of NiGHTS a couple months back.
It's quite light-weight and wearable, I expect it to be pretty comfortable once I line the inside of the cap with cotton. The outside is now going to be covered over with head-liner fabric (that's a thin sheet of open-cell foam-rubber applied to fabric, normally used on the inside of car roofs) which should smooth it out a bit and then I'll have satin over the top. The horns are as far down as I'm going to go with the nylon for now and the rest will be finished out and brought to a point with the headliner fabric and light polyester stuffing in the tips. I planned on also doing the widow's-peak with the foam rather than making it stiff, in the interest of comfort. The skeleton so far stays on my head quite well without any additional ties or support, which is what I was going for and why I made it cover so much and all the way down to my nape.
I will have the full costume finished up in time for Kumoricon on Labor Day weekend, so I'm going to be working on it pretty rapid-fire for the next couple weeks. After I finish up the hat (which I want to do by Friday to make use of a sale at Jo-ann Fabrics) I'll get back to working on the vest, which I started a month ago and then put aside. It and the boots are made out of thick vinyl.
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