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Viewing costume :: Chewbacca

Character Profile

Old Wizards, Farm Boys & Illegal Droids
Member:  Todzilla
Active Legion Member
Coruscant Base
Character Name:  Chewbacca
Costume Type:  Fringe
Species:  Wookiee
Old Wizards, Farm Boys & Illegal Droids
Home World:

Character/Costume Description

This Chewbacca was made 100%
from scratch with the exception of
the bandolier.

The stilts were made out of light-
weight plywood, Styrofoam and 1"
aluminum tubing. They provide 15"
of lift for a total costume height of
7'6". The toes were hand molded in
modeling clay, then a silicon mold
was made of them. A total of ten
toes were made from the mold
using Rigid Urethane Foam. The toes
were glued together and finished
using bondo. Finally they were
painted using acrylic paint.

The mask was custom sculpted off
of a lifecast. The mouth and nose
area are made from Eco-Flex
silicone. The entire skull is one piece
of Rigid Urethane Foam, that hinges
at the jaw . Metal cables are glue to
the underside of the upper lips to
provide a visible "snarl" when the
mouth is fully opened. High Strength
rubber bands are used to keep the
mouth in a closed position. Black
polyester mesh is connected at the
top and sides of the head and is
latch hooked with gray hair. The
remainder of the hair is glued
directly to the underskull. The first
layers of hair are glued to the
silicone using Silpoxy. The final
visible hairs are punched in. The
mustasche is 100% punched in.
Blue/gray contacts are used to
match the screen version of Chewie
and Ben Nye Midnite brown eye
makeup us used to blend in the
visible eye area to mask color.

The two piece suit is made out of
black polyester diving mesh. The
shirt is long sleeve with finger holes
built in so the back of the gloves are
covered. The pants are a basic
pajama design with drawstring and
suspenders. Suit is latch hooked
using kanekalon hair at an average
of 8"-9" lengths in the standard
Chewbacca color pattern. 60 packs
of #27 were blended with 30 packs
of #8 for the brown areas. 28 packs
of #44 were blended with 7 packs of
#4 for the dark gray areas. Gloves
are black, with the wrists and back
of hands being covered y latch
hooked mesh.

The bandolier is approximately 3"
wide and has 10 large boxes and 9
small boxes. The bag hangs on
Chewbacca's lower right hip.

For more pictures of this costume,
please see:


Pictures on other sites
 01. Roster Photo

 02. Pre-Costume for size comparison

 03. Front- Mouth Closed

 04. Front - Mouth Open

 05. Back

 06. Left Side

 07. Right Side

 08. Mask Detail (Front - Mouth Closed)

 09. Mask Detail (Front - Mouth Open)

 10. Mask Detail (Left)

 11. Mask Detal (Right)

 12. Left Foot

 13. Right Foot

 14. Left hand

 15. Right Hand

 16. Bandolier (Ammo box) Detai

 17. Bag Detail

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