I just finished making proper booties for my San cosplay which I hope to wear to Emerald City Comic Con in a couple weeks. I've been occasionally polishing and re-making parts of this costume since 2002 and now I'm getting serious about finally trying to get it 100% finished. XD
These were a bit tough to pattern and I'm not absolutely satisfied with them. I didn't like having to make the boot in two halves but I couldn't get the shape right any other way. The second boot turned out better than the first since it didn't have a million adjustments made, it was just cut from the pattern I drafted as I made the first one.
To get my basic foot pattern I put a plastic bag over my foot and taped it into a "skin" using masking tape (duct tape would work too), having padded my feet a bit under the bag to get the shape I wanted. Then I drew my seams onto the "skin" and carefully cut them to remove it from my foot. I created darts by slicing into curved surfaces with scissors to make them lay flat and then traced the pieces onto a suitable pattern fabric, adding a seam allowance. I made several mockup booties out of cheap, stiff fabric, adjusting the fit and transferring the changes to my pattern pieces. Once I liked what I had I cut into the pigskin suede I found unexpectedly at the fabric store, and sewed very very carefully on my sewing machine. (It's not wise to machine-sew leather unless you know your machine can handle it, but this stuff was quite soft.)
I used a fabric-hole-punching tool to make some eyelets for the leather laces to feed through so they stay at the proper levels. The back seam of the boot is open from the top of the heel upwards so that I can get my foot in, and ties closed with the laces.
Inside are some supportive, shaped insoles from the shoe store, and some cotton in the toe to give that rounded, dough-like look her feet often have in the film. I will probably make some slip-covers to protect the suede when I have to walk outside or on wet flooring.
Hope that helps anyone who is trying to make San's shoes!