Well, for SDCC 2024 I went a little overboard. I added another new costume to the Star Tours Crew; A Star Tourist. As well as made a few additions to the existing costumes.
First Off the OG Costumes (the ones in the middle).
Casting Off
I’ve wanted a Cast worn costume for years, but they are obnoxiously expensive on eBay. So I decided to add a couple additions to these uniforms to tie them a little closer to the ones in the park. Specifically the shoulder patches.
Pretty simple project, right? All I need is access to a embroidery machine and fabric that it close enough. Well, I have been asking a friend with an embroidery machine for years to help out and it’s never worked out. So…Plan B it is.
On the Shoulders of Giants
Gotta start with a template. I kinda guessed the proportions and came up with this:
Like mentioned before, the original idea was to get these embroidered. The basic plane was a reflective silver material, an Orange merrowed border (as opposed to the Red that Cast uniform has) and the ‘Arrow’ design applied as an iron on since I wasn’t sure if the machine could handle those shapes. However, lacking access to that machine I had to re-think this.
The silver material stayed the same but the merrowed border and the Arrow shape process was changed. Instead of embroidered edges, I went with red Bias tape and the arrows were done with iron on transfers.
I ended up making 3 different sizes of the shoulder patches. A lot of pinning, sewing, and ironing later I had pretty close replicas of the original patches.
The longest patches went on my uniform and a the medium length ones took a trip to LA to go on the Flight Attendant uniform (ignore the button clasps on her uniform, they never made it off the dress form.
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A fun little addition, soley for Cast members, I added a yellow pull tab to her belt. Safety First.