As promised, here are the costumes I made for the boys. First, an explanation. It was not my original intention to "make" costumes. The wife had "bought" costumes for the boys at the Dollar store. These included a helmet, shield, chest plate, tiny machine guns, and some glow wear. She had figured she could create some kind of costume out of this arrangement. Turns out, the helmets were evidently made to fit a doll's head. Either that, or the Chinese people making them have tiny perfectly round heads. Regardless, they wouldn't fit the boys.
So, I started by just trying to make them fit, which included cutting the back half off and expanding it with duck tape. (Red Green is my hero!) Still, the helmets only covered their scalp and eyes. Next thing I know, I'm adding aluminum foil sandwiched between clear box tape to cover the face. The boys where so happy with that, they encouraged me to continue. I started crafting pants out of alternating strips of Aluminum foil and duct tape. Then added some electrical tape to the back for the "flexible" look. Eventually, everything was covered with clear box tape.
The oldest decided he wanted a "jetpack". I took the shield my wife bought, turned it upside down and added 3 Toilet paper rolls covered in aluminum foil, some red foil for a flaming effect, and clear tape; then fastened the shield to the chest plate with foil shoulder straps. The youngest decided he DIDN'T want a jetpack, which I think is saying something.
After putting everything on, I saw the need for accessories and made the arm bands and waist protectors/belts. More aluminum foil sandwiched between clear tape.
The boys loved them. They wore them on at least 3 different occasions (which meant constant repairs.) I probably spent enough on tape and foil to buy a couple of costumes. They did win $25 in a costume contest, but unfortunately the wife wouldn't let me subtract my labor and material cost from that. Greedy little ingrates split their winnings and bought Webkins animals and Chaotic cards.
Here's the pics. I present the "Star Wars Assassins" or "RoboTroopers", or whatever else they told people they were, which changed each time.