I'm not of much help regarding the costume construction but I can say that I dig this idea! It sounds really cool/unique and still recognizable! I can't wait to see photos if you decide to do it!
Masamune Date - Sengoku Basara
Team Aqua Grunt (male) - Pokémon Ruby/Sapphire Version
*~Next con I'm attending~*
FIN Kemin mangapäivä (11 October 2014)
SAT Taregard Frir - Original Character