My friends and I are firm believers that if you have a costuming niche, you should totally
exploit it use it your benefit. A great example was this amazing Scotty at DragonCon:
I, of course, have my Asian niche. I do try to branch out sometimes and try non-Asian characters (they are costumes, after all), but people are always less confused when I’m an Asian character.
My husband’s niche is Nathan Fillion. He really does have an uncanny resemblance to him. He’d gone as Captain Hammer the last two years, so when our friend said she wanted to go as Zoe from Firefly this year (she’s got the Black female niche covered), I decided my husband had to be Mal.
From browsing some of the Firefly fan sites, I know that some hardcore Browncoats drop serious cash buying or making exact replicas of the costumes and props used in the show. I was just going for passable, though, so this is what I came up with.
The (mostly) authentic pants cost upwards of $50, so I found some khakis on clearance at Walmart for $7, ripped off the beltloops, changed the back of the waistband, added jean buttons for suspenders, and added stripes down each side with brown grosgrain ribbon.
I bought some replacement suspender ears with sew-on attachments off of eBay for a few dollars and made some suspenders out of brown bottomweight material (I couldn’t find canvas in the right color, and I didn’t feel like dying anything).
Boots are expensive! While I can (sorta) justify spending money on boots for myself because I can wear them again, there is no place in my husband’s non-costume wardrobe for knee-high boots. I was looking around for cheap men’s boots to no avail when I learned that Mal’s actual boots from the show were just slip-on Steve Madden shoes with spats glued on to them. So my being cheap was actually leading to a more authentic boot! My husband happened to have a pair of brown shoes that he hated that were close enough to the Steve Madden shoes. I made spats out of brown vinyl and glued them on with rubber cement. I meant to paint/weather the vinyl to give the boots a more uniform appearance, but I never got around to it. Maybe next year.
The holster was made with some leftover brown vinyl scraps, brass studs, and a sandal buckle (the same ones I use in Zoe’s costume below). I coated the back of the vinyl with a layer of glue to stiffen it a bit. The back and edges of the vinyl are white, so I painted them with brown acrylic paint to make them look more like real leather.
I also helped my friend with her Zoe costume.
I happened to have the McCall’s M5800 pattern on hand, and the bodice had the right princess seams for Zoe’s vest.
I didn’t realize until after I already made the costume that the back isn’t exactly right (Zoe’s had one seam down the back instead of two princess seams), but I don’t think most people cared. I lengthened it a bit as the bodice was supposed to hit at the waist, and Zoe’s vest is a bit longer. I opened the two side seams and added four sandal buckles on each side (I found a pack of 20 for $5 on eBay!).
The holster is basically a T with one side of the top arm longer than the other. I used a gold buckle that was leftover from another costume, so it’s not quite as big as Zoe’s, but it worked. I didn’t have a shotgun shell on hand, so I used a AA battery as a guide in making the bullet holders. In hindsight, I should have tried to get my hands on some fake bullets so that if she ever intends to put some in there they’ll be functionable. The real holster had a hook to hold the gun in place, but becasue my holster was not made of stiff leather, there was no way to put a functioning hook on. I sewed on a couple of straps instead, which means that in a gunfight, my Zoe would be shot before she could get the first strap unbuckled, but it looked fine.