I'm new to the whole cosplay world, but have been building custom Halloween pieces for quite some time and thought I would share my project from Halloween 2012. These claws are made out of 1/4" thick aluminum and the measurements and bevel design are based off the X1 Hero claws that I obtained from the owner of that set. This project was a labor of love as each blade took 8hrs a piece to cut, grind, hand file, sand, polish, etc. I have built 2 subsequent sets for private collectors that were ordered non-polished as the polishing washes out the bold look of the bevel in the blades. Pictured are build pics of my proto set from start to finish, along with a couple quick costume pics. Enjoy!
Smoothed out bevel
Completed polished set