First off, the side plates, although authentic, didn't quite work in terms of adjustability and flexibility. The easiest way to solve this was to simply stitch the two sides together and use a bag draw string snap to keep it in place.
I also sewed up the sash which was pretty easy. I trimmed it with a bit of "battleship grey" twine. That's one more piece down!
Thinking ahead, I thought it might be easier to use if it were actually attached to the costume somehow. Basically I took more bag strap and sewed the sash to that, then attached the bag strap to the rear plate with more of the twine stitching I've been doing all over the costume.
With that taken care of, I started working on the hat/mask. I took apart an old baseball hat and used that as a sort of design guide. I first sewed up a piece of foam padding inside of some cloth, and attached some bag straps with velcro at the end.
Side note: The kids head is 19 and 3/4" around. Mine isn't a whole lot bigger than that. Wow.
I then sewed on a rather large piece of material. Given that I have no idea how much material I'll need or how the heck I'm going to sew this up I thought it was a good idea to be safe.
I then test fit the thing on Wee Ninja. I quickly discovered that I needed a way to secure the shape when on his head because once you take it off there's no way to tell where the shape started/ended. My wife suggested bobby pins. I've never used a bobby pin before and that's not something I think I want to learn how to do.
I know! I use Tape a lot:
Ahhhh yeaaaaah.
At this point I'll admit that it looks like either an over large do-rag or something that an orthodox Muslim woman would wear but after I get the shape on top sewn up I'll worry about the rest.
That's where I'm at for now. Only the hat/mask and the forearm guards to go! More to come!
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