This particular costume I didn't unfortunately have the opportunity to make myself, and had to commission, due to massive time issues, because of work, collage and few other things.
The mask and sword, Tensa Zangetsu, though I did on my own time....in less then a week.
In the original plan, I had planned to make the costume myself, but then I got slammed and it all just fell to the back burner.
The mask is made from comic backing board and done using glue, markers and held on with Duct tape. I actually picked up the rough ideas on how to construct it from someone here at Cosplay.com, though I can't recall who. But I thank them for there simple tutorial.
The sword itself, was constructed utilizing a 41" bokkun (wooden sword: katana-like style), two types of ribbon (Red braided and black flat ribbed), balsa wood, spray black gloss paint, clear laquer paint, some silly putty, glue, duct tape, a charm bracelet chain modified and painted black, and a guitar pick stolen from my little sister painted black. The poor guard didn't survive the weekend, but at least made it though most of it....including a masqurade, being through a game of cosplay shougi, a handful of mock battles, and being dropped several times. I'll pull it out again, to reprise, but will have to replace the guard before then, with stronger wood.
Youmacon '06 -Debut
Anime Central X ('07)