So some friends of mine in Michigan wanted to do a Super Robot theme entry to go with Katsucon 8's upcoming theme. We decided on Mazinger Z and after watching Rob play Super Robot Taisen endlessly, I fell for the moronic Boss Borot. A useless robot piloted by an idiotic coward! Not to mention, no weaponry...
Anyway, Fanime was coming up and I was slated to go work a table there. Since it was the first (and so far only) time I've ever done a West-coast con, I decided that I wanted to compete. And I don't compete unless I make something worthy of winning. So I figured robots were a good choice, it would give me practice for the costumes to make for next Katsu, and spent a month working on a costume the CAN fit inside one suitcase.
Boss attaches via velcro at all the major joints. Initially, I had no ventilation, so Fanime was uncomfortable. Afterwards, Dad helped me install a small fan in the back (hidden inside a gutted fire alarm casing) and we put netting in the head for air to flow. I also made air holes down the back of the legs to help.
The feet were initially built around packaging foam, but that was thoroughly crushed down at Fanime. We cut into the feet and replaced the innards with firm padding used for gardening (those kneeling pads) and by the time Katsu rolled around, I had to lengthen Boss' legs cause of the height difference in who wore it for the skit.
So a costume that started as a lark ended up getting used in the skit. And Rob can breakdance in it! Not well... but he dances. *Grins*
Fanime 2001: "Technical Excellence in the Individual Category" (still not sure what that is)
Anime North 5: "Best Use of Foam and Materials"
Katsucon 8 (2002): Best Presentation/Master Division (group skit)
Katsucon 8 (2002): Best in Show (group skit)