This is a Lord of the Rings Sauron costume I made for my son. When he told me he wanted to be Sauron for Halloween, I wasn’t really sure how to pull this off. I started with the “easy” parts.
I purchased a costume grade set of shoulder pads and attached layered/shredded black fabric.
The hands started out as zombie hands from a local Halloween store. I added the armor pieces made out of a material called Wonderflex. It’s basically a heat and shape plastic product that cools very hard. The final touch was a replica of the One Ring.
All of the armor pieces were made of Craft foam and Wonderflex. Each piece was individually cut and molded into shape. All pieces were painted a dark grey and finished with a dry brush of black.
The helmet was the hardest part. It was pieced together with Wonderflex. In order to get the really sharp edges needed, I covered the edges in paper clay and sanded them down. This was also painted grey/black.
All of the scroll details on the armor and helmet was done with a hot glue gun. Time consuming, but pretty easy.
The mace was a piece of PVC pipe with wood accents and plastic blades on the end.
The final outcome was really better than I expected and my son was thrilled. It was difficult to get in and out of, but not too uncomfortable to wear. Vision from the helmet was a little bit obstructed. That’s the condensed version of the costume build. I hope you all like it.
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