The real challenge of this costume was not the sewing, but the construction of the metal arm and leg. I was determined to be the first person in the US to have made Ed's arm AND leg out of real metal (I don't know if I was or not) and I got them done in time for AnimeBoston 2005, where I participated in the masquerade and won an honorable mention for the costume.
However, the metal was dangerous. It bruised me quite badly in several places and cut me once or twice, so I retired it in favor of plastic auto-mail. (Ie. V.4)
AnimeBoston2005 masquerade honorable mention