Editing Wookiee Bodysuits

[[Category:Costumes]]

[[Category:Costumes]]

[[Category:Chewbacca]]

[[Category:Chewbacca]]

[[Category:Star Wars: Episode I: The Phantom Menace]]

[[Category:Star Wars: Episode I: The Phantom Menace]]

[[Category:Star Wars: Episode III: Revenge of the Sith]]

[[Category:Star Wars: Episode III: Revenge of the Sith]]

[[Category:Star Wars: Episode IX: Rise of Skywalker]]

[[Category:Star Wars: Episode IX: Rise of Skywalker]]

=== Original Trilogy Suits ===

=== Original Trilogy Suits ===

==== Star Wars: Episode IV: A New Hope ====

==== Star Wars: Episode IV: A New Hope ====

==== Solo: A Star Wars Story Sound Book ====

==== Solo: A Star Wars Story Sound Book ====

# According to his [http://petermayhew.com/peter.html personal website], Peter Mayhew was 7‘3” tall.

# According to his [http://petermayhew.com/peter.html personal website], Peter Mayhew was 7‘3” tall.

# According to the [https://web.archive.org/web/20080325095249/http://www.starwars.com/databank/character/chewbacca/?id=bts Chewbacca Behind the Scenes] entry on the Official Site's Databank, "Numerous versions of the suit were made to handle the wear and tear of film making.

# According to the [https://web.archive.org/web/20080325095249/http://www.starwars.com/databank/character/chewbacca/?id=bts Chewbacca Behind the Scenes] entry on the Official Site's Databank, "Numerous versions of the suit were made to handle the wear and tear of film making.

# According to a [http://www.theforce.net/jedicouncil/interview/mayhew.shtml TheForce.Net Interview with Peter Mayhew], Mayhew used his stunt double for the first and only time in Return of the Jedi when the skiff he is on gets hit and tilts violently. It is likely that a stunt suit was created for this purpose.

# According to a [http://www.theforce.net/jedicouncil/interview/mayhew.shtml TheForce.Net Interview with Peter Mayhew], Mayhew used his stunt double for the first and only time in Return of the Jedi when the skiff he is on gets hit and tilts violently. It is likely that a stunt suit was created for this purpose.

# The dark hair on his knees only covers the outside half of his legs, not the insides.

# The dark hair on his knees only covers the outside half of his legs, not the insides.

# According to Bob Kohn, the correct NFTech loom code for the Revenge of the '''Sith hair is AJ 2872 Brown, 15" sliver Chewbacca''' for the brown and '''AJ 2873 Grey 15", sliver Chewbacca''' for the grey.

# According to Bob Kohn, the correct NFTech loom code for the Revenge of the '''Sith hair is AJ 2872 Brown, 15" sliver Chewbacca''' for the brown and '''AJ 2873 Grey 15", sliver Chewbacca''' for the grey.

The most popular method is to use synthetic “Kanekalon” hair extensions which can be purchased inexpensively from beauty supply shops. This method is far less expensive than using hair from National Fiber, but the trade off is that it is extremely time consuming and labor intensive.

The most popular method is to use synthetic “Kanekalon” hair extensions which can be purchased inexpensively from beauty supply shops. This method is far less expensive than using hair from National Fiber, but the trade off is that it is extremely time consuming and labor intensive.

The hair is tied into a suit made of a mesh fabric. It is not that different from building a giant wig. For all of my Wookiee suits I have purchased the mesh at army surplus stores. It is a medium mesh that is camouflaged and comes in unmarked plastic bags and sells for $8 - $10 per bag. I think I needed two or three bags for the full suit.

The hair is tied into a suit made of a mesh fabric. It is not that different from building a giant wig. For all of my Wookiee suits I have purchased the mesh at army surplus stores. It is a medium mesh that is camouflaged and comes in unmarked plastic bags and sells for $8 - $10 per bag. I think I needed two or three bags for the full suit.

[http://www.forum.rebellegion.com/forum/viewtopic.php?p=245335#245335 Duck’s tutorial] offers some excellent design tips and drawings on the creation of the mesh suit. Many others have also offered advice on the design of the mesh suit, so here is a list of tips.

[http://www.forum.rebellegion.com/forum/viewtopic.php?p=245335#245335 Duck’s tutorial] offers some excellent design tips and drawings on the creation of the mesh suit. Many others have also offered advice on the design of the mesh suit, so here is a list of tips.

Here are Duck’s excellent drawings. Click to enlarge.

Here are Duck’s excellent drawings. Click to enlarge.

Once you have finished sewing your mesh suit, you will want to mark off where the gray areas will be. Because of the length of the hair, your gray areas will start 8" - 10" down from where you start tying in gray hair. This means your horizontal marks need to be offset to compensate for this. Your vertical marks do not.

Once you have finished sewing your mesh suit, you will want to mark off where the gray areas will be. Because of the length of the hair, your gray areas will start 8" - 10" down from where you start tying in gray hair. This means your horizontal marks need to be offset to compensate for this. Your vertical marks do not.

The hair to use is Kanekalon synthetic hair, specifically Kanekalon Jumbo Braids. You want the regular Kanekalon Jumbo braids, as these have a matte or "Yaky" finish to them. Avoid hair marked "Silky" as these have a shiny finish. These can be found in beauty supply shops in almost any city. They typically sell for $2.00 to $3.00 per bag in the U.S. The hair comes in a folded braid that, when unfolded, is 48" long.

The hair to use is Kanekalon synthetic hair, specifically Kanekalon Jumbo Braids. You want the regular Kanekalon Jumbo braids, as these have a matte or "Yaky" finish to them. Avoid hair marked "Silky" as these have a shiny finish. These can be found in beauty supply shops in almost any city. They typically sell for $2.00 to $3.00 per bag in the U.S. The hair comes in a folded braid that, when unfolded, is 48" long.

So how many bags do you need? None of us seem to take detailed notes and just stop counting, but generally most estimates are somewhere in the neighborhood of 50 - 60 for the brown areas and maybe another 20 of the gray areas.

So how many bags do you need? None of us seem to take detailed notes and just stop counting, but generally most estimates are somewhere in the neighborhood of 50 - 60 for the brown areas and maybe another 20 of the gray areas.

Before you tie the hair into your mesh suit you will need to do a few things to prepare it first.

Before you tie the hair into your mesh suit you will need to do a few things to prepare it first.

As noted earlier, use a 30/70 mix of #27 and #6 for the brown sections with some #8 for highlights, and a mix of #4 and #44 (or #51) for the gray sections. To achieve a 30/70 mix, mix one bag of the first color (#6 for the brown areas, #44 for the grey areas) with two bags of the second color (#27 for the brown areas, #4 for the grey areas).

As noted earlier, use a 30/70 mix of #27 and #6 for the brown sections with some #8 for highlights, and a mix of #4 and #44 (or #51) for the gray sections. To achieve a 30/70 mix, mix one bag of the first color (#6 for the brown areas, #44 for the grey areas) with two bags of the second color (#27 for the brown areas, #4 for the grey areas).

[http://wookiee.de/kostuem.html Alexander from Germany] opted to use hot glue to attach his Wookiee hair to a cotton suit. Years ago when I was first researching my own Wookiee suit I attempted to use this method and found several disadvantages:

[http://wookiee.de/kostuem.html Alexander from Germany] opted to use hot glue to attach his Wookiee hair to a cotton suit. Years ago when I was first researching my own Wookiee suit I attempted to use this method and found several disadvantages:

# It tends to be slower, because you have to wait for the glue to cool.

# It tends to be slower, because you have to wait for the glue to cool.

However, one cannot argue with Alexander’s results, so it’s an option you might consider.

However, one cannot argue with Alexander’s results, so it’s an option you might consider.

Once your mesh suit and hair are are ready to go, you can begin the process of latch-hooking hair into the suit. This is a time-consuming and tedious process, and you can expect to spend 100 or more hours on this part of the costume. However, once you have the basic technique mastered, hooking hair into the suit is not especially difficult, and many costumers simply pass the time by watching a movie while they work

Once your mesh suit and hair are are ready to go, you can begin the process of latch-hooking hair into the suit. This is a time-consuming and tedious process, and you can expect to spend 100 or more hours on this part of the costume. However, once you have the basic technique mastered, hooking hair into the suit is not especially difficult, and many costumers simply pass the time by watching a movie while they work

On my first suit, I opted to use a pair of hemostats, which are locking medical tweezers with a curved nose. However, by the time I made my second suit I had learned how to use the latch-hook properly and found it to be much faster and easier.

On my first suit, I opted to use a pair of hemostats, which are locking medical tweezers with a curved nose. However, by the time I made my second suit I had learned how to use the latch-hook properly and found it to be much faster and easier.

# The knots should be arranged in overlapping rows so that the knots on a given row cover the space between the knots on the row below it.

# The knots should be arranged in overlapping rows so that the knots on a given row cover the space between the knots on the row below it.

Once you try your suit on for the first time you will notice how bushy it is. This is because there is way too much hair. This is a much better problem to have than not enough hair.

Once you try your suit on for the first time you will notice how bushy it is. This is because there is way too much hair. This is a much better problem to have than not enough hair.

[http://www.daxhaircare.com/store/dax-styling-waxes/ DAX Pomade Hair Wax]

[http://www.daxhaircare.com/store/dax-styling-waxes/ DAX Pomade Hair Wax]

[http://www.ehow.com/how_8157163_wash-kanekalon.html How to Wash Kanekalon]

[http://www.ehow.com/how_8157163_wash-kanekalon.html How to Wash Kanekalon]

New method using glued on hair wefts. Wefts are hair extensions that come pre-sewn to a strip of cloth. Steve Bornhoeft used human hair wefts to build his first suit.

New method using glued on hair wefts. Wefts are hair extensions that come pre-sewn to a strip of cloth. Steve Bornhoeft used human hair wefts to build his first suit.

[http://www.nftech.com/ National Fiber Technology] in Massachusetts is the only company on the planet that makes a long hair fabric fur. They supplied the hair for the Wookiees in Revenge of the Sith. The hair is excellent but very expensive. Costs can vary anywhere from $2500 to $3500 depending on how much you need.

[http://www.nftech.com/ National Fiber Technology] in Massachusetts is the only company on the planet that makes a long hair fabric fur. They supplied the hair for the Wookiees in Revenge of the Sith. The hair is excellent but very expensive. Costs can vary anywhere from $2500 to $3500 depending on how much you need.

[https://www.stanwinstonschool.com/tutorials/how-to-body-cast-create-custom-mannequin-on-a-budget How to Body Cast and Create a Custom Mannequin on a Budget]

[https://www.stanwinstonschool.com/tutorials/how-to-body-cast-create-custom-mannequin-on-a-budget How to Body Cast and Create a Custom Mannequin on a Budget]

Bob Kohn used a body suit pattern, similar to the ones used by Stormtroopers. Plan out your patterns on the suit, then cut the suit based on patterns and fur colors. Bob’s pattern used something like 40-50 pieces to sew back together when finished. Remember to add seam allowance.

Bob Kohn used a body suit pattern, similar to the ones used by Stormtroopers. Plan out your patterns on the suit, then cut the suit based on patterns and fur colors. Bob’s pattern used something like 40-50 pieces to sew back together when finished. Remember to add seam allowance.

Fabric furs have a certain direction that they must hang or lay. This is the fabric’s "nap." The idea is that the hair will all hang down when the finished costume is worn. You will not simply be able to place your pattern pieces wherever there is room; the pattern pieces must have the correct orientation with respect to the nap. This will increase the amount of hair you will need, so plan for this in your patterns and don’t forget about it when you cut.

Fabric furs have a certain direction that they must hang or lay. This is the fabric’s "nap." The idea is that the hair will all hang down when the finished costume is worn. You will not simply be able to place your pattern pieces wherever there is room; the pattern pieces must have the correct orientation with respect to the nap. This will increase the amount of hair you will need, so plan for this in your patterns and don’t forget about it when you cut.

* Pay special attention to the neck. Make sure most of the neck opening (about ⅔) is on the front.

* Pay special attention to the neck. Make sure most of the neck opening (about ⅔) is on the front.

Most Wookiees choose "medium brown" and "dark grey" and end up with colors that are too red and too light. Bob Kohn made his suit using National Fiber hair and has obtained the correct colors to use. For brown, you want to order '''AJ 2872 Brown, 15" silver Chewbacca''', for the grey you want '''AJ 2873 Grey, 15" silver Chewbacca'''. Bob Kohn estimates that you will need approximately 17 square feet of the grey hair, and 27 square feet of the brown hair. Bob says you will also want to get 1 pound of loose hair of each color for use on your mask.

Most Wookiees choose "medium brown" and "dark grey" and end up with colors that are too red and too light. Bob Kohn made his suit using National Fiber hair and has obtained the correct colors to use. For brown, you want to order '''AJ 2872 Brown, 15" silver Chewbacca''', for the grey you want '''AJ 2873 Grey, 15" silver Chewbacca'''. Bob Kohn estimates that you will need approximately 17 square feet of the grey hair, and 27 square feet of the brown hair. Bob says you will also want to get 1 pound of loose hair of each color for use on your mask.

It’s important to remember that the above numbers are just a loose figure; you need to pattern your suit before you order your hair and order based on that.

It’s important to remember that the above numbers are just a loose figure; you need to pattern your suit before you order your hair and order based on that.

Read [http://www.forum.rebellegion.com/forum/viewtopic.php?p=222979#222979 Kitfox’s discussion of Shawn’s suit]

Read [http://www.forum.rebellegion.com/forum/viewtopic.php?p=222979#222979 Kitfox’s discussion of Shawn’s suit]

Bob Kohn learned the hard way that you should NOT use a serger with NFTech fabrics. The heat created by the serger needles melts and breaks down some of the chemicals in the hair; which then attach themselves to the needles and form razor sharp debris that shreds the base fabric. Instead, use a traditional sewing machine and use a wide zigzag stitch. Bob and his wife spent a year repairing the suit after the fact.

Bob Kohn learned the hard way that you should NOT use a serger with NFTech fabrics. The heat created by the serger needles melts and breaks down some of the chemicals in the hair; which then attach themselves to the needles and form razor sharp debris that shreds the base fabric. Instead, use a traditional sewing machine and use a wide zigzag stitch. Bob and his wife spent a year repairing the suit after the fact.

Bob Kohn says that the National Fiber Hair is beautiful right off of the bolt, and almost no grooming is required to achieve the distinctive wavy Chewie look. He recommends doing nothing but rolling the suit up and storing it a bag after every troop and cleaning. After 1-2 troops, you will start to see the distinctive wavy look that are you looking for.

Bob Kohn says that the National Fiber Hair is beautiful right off of the bolt, and almost no grooming is required to achieve the distinctive wavy Chewie look. He recommends doing nothing but rolling the suit up and storing it a bag after every troop and cleaning. After 1-2 troops, you will start to see the distinctive wavy look that are you looking for.

The mesh fabric will absorb sweat and begin to stink if not cleaned. The key to keeping the suit clean is to allow the suit to air out immediately after every event, not 12 hours later. Consider hanging it in your car like your dry cleaning or build a collapsible coat rack in your bin. Febreeze is also very helpful. However, these techniques have their limits, and eventually you will need to wash it by hand.

The mesh fabric will absorb sweat and begin to stink if not cleaned. The key to keeping the suit clean is to allow the suit to air out immediately after every event, not 12 hours later. Consider hanging it in your car like your dry cleaning or build a collapsible coat rack in your bin. Febreeze is also very helpful. However, these techniques have their limits, and eventually you will need to wash it by hand.

To dry, gently lay the suit down on a bunch of towels and pat dry the suit with another towel. Do not be aggressive; this is not your dog that are drying. Flip the suit and repeat, replacing towels as you go. Once the suit has been sufficiently hand-dried and it is no longer heavy with the weight of all that water, hang the suit and allow it to air dry. It’s important to towel dry first; hanging the heavy, water-logged suit could damage it. Bob Kohn uses a clothesline on a sunny/light breezy day. If you live in a humid or wet climate, consider using a large fan. Avoid blow drying as you could damage the suit.

To dry, gently lay the suit down on a bunch of towels and pat dry the suit with another towel. Do not be aggressive; this is not your dog that are drying. Flip the suit and repeat, replacing towels as you go. Once the suit has been sufficiently hand-dried and it is no longer heavy with the weight of all that water, hang the suit and allow it to air dry. It’s important to towel dry first; hanging the heavy, water-logged suit could damage it. Bob Kohn uses a clothesline on a sunny/light breezy day. If you live in a humid or wet climate, consider using a large fan. Avoid blow drying as you could damage the suit.

Faux fur doesn't work, not long enough. More notes to follow.

Faux fur doesn't work, not long enough. More notes to follow.

Passable with extensive modification in the past, but more expensive than other methods and still a lot of work for a mediocre result. Not accepted by the 501st or Rebel Legions. Also, Rubies went out of business during the COVID-19 pandemic.

Passable with extensive modification in the past, but more expensive than other methods and still a lot of work for a mediocre result. Not accepted by the 501st or Rebel Legions. Also, Rubies went out of business during the COVID-19 pandemic.

Anovos had a prototype commissioned a few years back and showed it off at San Diego Comic Con. They decided not to pursue it as a commercial project.

Anovos had a prototype commissioned a few years back and showed it off at San Diego Comic Con. They decided not to pursue it as a commercial project.