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Okay great! Think my wife has a template ready. Most likely will do a velcro enclosure to have the neck fit nicely. And also so her hair does not get stuck in a zipper!

Okay. So neck seal. I am thinking the best way to tackle it would be to make the mask and the neck seal separate. We have been trying to make it to where the face mask and neck seal were one piece, but getting the neck to conform without bunching up has been a nightmare.

Here is the link to my test. Will do another when the blades arrive.

CRL reference saber progress! Still need to manufacture some sort of speaker cover, and will probably be relocating the swing sensor, but will likely wait until the blade material arrives. I will be uploading the video for this later on as well.

I was looking at those for my wife as well beforehand. The maker does state they are for costuming only and NOT for dueling. For some reason he has the black and silver in the wrong order as well. Take a look at my thread as I will be updating it when i progress. I am making dueling quality sabers using the CRL reference(which is wrong, I know, but it matches what is depicted on the CRL anyways). I am using pvc electrical conduit and installing electronics and a blade. It will be cost efficient, total for 2 sabers will be under $100 and be strong enough to duel as stated before. I may end up offering sabers for sale after wards, depending on how my build goes.

Oh no i won't be using the 3d printed hilts for her actual sabers. That is what the pvc hilt next to it is for. I should be done assembling the main body of the hilt tonight or tomorrow. And the electronics should be here soon. And that was my thinking for the bracers. Been searching everywhere locally and found some close at tandy leather, but not close enough :/ Thanks for keeping an eye out for us!

So we are thinking of using a black jersey knit for the mask/neck seal. Thinking lycra might be too reflective for it. Also, i assembled the main portions of one of the 3d printed hilts, and as cool as they are(and awesome when we can superimpose blades on them), they are just too small to install any type of electronics into it. So on to plan B. Plan B is to custom build sabers according to the circular sabers shown in the CRL. I am using PVC electrical conduit that comes bent from the store, and some pvc couplers as well. It is a pretty easy hilt to manufactur, and they will provide ample room to install a soundboard, high powered led, and batteries, alonrg with housing a blade.I got most of the components from The Custom Saber Shop, and the polycarbonate tubing from Amazon(ordered 6' of 1" OD, 7/8" ID, and 1/16" wall thickness for $21). This will allow me to cut the tubing in half for both sabers being 36" each(i may end up cutting it down to 32" but we will see). I am also gutting a hasbro blade builders saber to use the speaker and soundboard(with plans on upgrading later). Luckily, they are on clearance at walmart for $10 each . Here is the partially assembled 3d printed hilt. The CRL photo for reference My findings at Home Depot compared to the 3d hilt. And where i am at now. I still need to add another section of pvc, and then another trimmed down coupler. Also, for the vambrace straps, i did find this online, and was hoping to get everyones thoughts on them. If they wouldn't work, i will manufacture some out of sintra for now, and continue searching for metal buckles.

Im thinking for the hood, i can use the lycra fabric and bond it to eva foam. Kind of 2 birds with one stone, and i have eva foam handy

Thanks for the replies! That material definitely looks perfect! Thanks for that! The second picture did not give me a thickness, although it seems very close to the fabric in the link you provided

Ok. For the neckseal and mask. I have been looking at neoprene. Which do yall think would work best. https://www.amazon.com/gp/r.html?C=14BVG2MSIYJVS&R=2A05WLH3YJND4&T=C&U=https%3A%2F%2Fwww.amazon.com%2Fgp%2Fproduct%2FB00TXV606A%2Fref%3Dpe_58000_230938520_em_1p_1_ti&A=7LY8JYZAWOOGPODZ0XORIEHTQCYA&H=AFDAYIKTO8NUS1JEEAIC3KP7S9IA&ref_=pe_58000_230938520_em_1p_1_ti Or this lycra https://www.amazon.com/gp/r.html?C=14BVG2MSIYJVS&R=2A05WLH3YJND4&T=C&U=https%3A%2F%2Fwww.amazon.com%2Fgp%2Fproduct%2FB005Q107H4%2Fref%3Dpe_58000_230938520_em_1p_0_ti&A=01LDFJI4R39ZMLXI883ASCKXJGWA&H=FJEADAAMRYBQCSINW3MH0QIAYOOA&ref_=pe_58000_230938520_em_1p_0_ti

Quick update. After getting my wifes duct tape mannequin done, she was able to form fit her main body. In the picture, she rolled the boots down to size as a mock up on when we take them down. Also, update from my friend who was 3d printing her saber hilts...and they are ready for pick up! I plan on installing electronics and blades in them as well. Never done that before!

LadyB, your sash looks fantastic, just have had a hard time sourcing that material. Where did you get your arm bracer buckles, btw? I was considering making them out of sintra, but would much rather have real metal enclosures as it appears you have.

That was our concern. The taffeta we have found locally has that sheen to it. I am not saying all taffeta is like that, just what happens to be in store down here. We are also hesitant to order fabric online because we would much rather be able to look at it physically before committing to a purchase.

Would this be the fabric used for the sash? http://www.joann.com/david-tutera-fabric--stretch-taffeta-red/13849922.html#q=Taffeta%2Bfabric&prefn1=prod_type&sz=36&start=37&prefv1=Product

That was my thinking. We have a Pfaff(i think thats how its spelled) that was given to us and barely used, and she mainly uses her Brother Project Runway machine. The material is fairly thin, and stretchy. I think handsewing is definitely an option for these as well...going to have her try them on again and see if maybe we can even fold them inside to shorten them, just to see how it looks at least.