Kylo Ren
Helmet
The helmet was modeled by JTM on Thingiverse and I modified it by cutting off the front piece.(cut version here) After printing I covered it in bondo and filler primer several times, sanding it down each time. Once I got everything to a point that I liked, I did a few more coats of primer and polished it with some steel wool. I used the Anovos helmet as a guide for the weathering and battle damage and cut it in with my dremel.
Helmet Painting
I started with a base coat of silver, then masked off the upper face and sprayed truck bed liner for texture. Instead of satin black I opted to use a black stainless steel color for the main part of the helmet. I later went in and added black in between the lines on the upper face and silver to the battle damage.
Helmet Mechanism
I wanted the helmet to move like it does in the movie, so I cut the very front piece off. I used an Elegoo Uno R3 and a micro servo combined with a 3d printed servo to linear actuator system to achieve the movement. A video and link to the printable files can be found here. The helmet also has a voice changer that I got from a Halloween store some time ago, but the camera wouldn't pick it up.
86361065_3245753278770639_4151437061184139013_n.mp4
Lightsaber
For the lightsaber, I 3d printed the files found here. This was my first prop printed using my Elegoo Mars and I was amazed at the finish straight off the printer. After sanding and minimal filling, I gave it a coat of the black stainless steel paint that I used for the helmet. After that I followed the paint scheme of a few versions. I also added the end of a chain door lock so I could attach it to the belt.
Fabric
For the sewn parts I modified a McCall's pattern. The sleeves and tunic started as 12 feet of fabric and were compressed down to 4 by the time I got finished with all the pleats. The belt is faux leather with two layers of interfacing and 1/8 inch upholstery foam in between. All the piping on the costume was made by sewing paracord into bias tape. The gorget is made of a vinyl base with jersey liner and has strips of faux leather sewn around it. The belt has the lock part of a chain door lock with the top cut off for attaching the lightsaber.
Kylo was a really fun costume to make and wear. I really wanted to learn the coding and wiring for the helmet and it was a bit rocky at first, but I enjoyed it once I got the hang of it.