Gorath Tsu
I'll admit that my past anime cosplay costumes have been purchased. I always added things to them to spruce them up, but the majority of the outfits were purchased from an online store. But that was years ago...
My Star Wars: Episode VI - Return of the Jedi B-wing pilot outfit, however, is almost entirely hand-made here at home except for parts that I couldn't make, like gloves and boots, and some details (flares, code cylinders, which are machine-made by a prop-maker). Everything else about the costume-- flak vest, belt, ejection harness, gaiters, cap, hose cover, belt box, are all made here at home. Even my chestbox and helmet I made myself. In the case of the helmet, I actually made a clay model of it, then made a rubber mother mold, and cast a helmet in resin and fiberglass. I'm planning to make a new chestbox in resin/fiberglass as well, my current chestbox is mostly foam and Paperclay. I'm currently working on a new flak vest that's more accurate.
The only other thing thing that wasn't made here were my coveralls, which are a pair of Dickies, but I had to add a number of pockets to them.


OMG that sounds so Awesome!
Are those photos at the bottom of the post? Sadly my pc won't show them to me.
For this year's halloween, I was thinking of making Queen Amidala's military outfit from Star Wars Episode one.