It's difficult to calculate how long this project has taken me. I started actual construction efforts in May 2004, with the arm bracers. As time went on I shifted back and forth between the mask and the armor. This allowed for two things. One, I could use inspiration and creativity as it came to me on both projects without being burned out. And two, a lot of this stuff needed time to dry.
If you decide to take on a similar project I highly recommend that you flesh out your design as much as possible before going into construction. This includes practice. One thing I notice on many different fan sites is that you see the final result; the end product of months of efforts. What you don't see, and what you rarely hear about are all the problems. It's easy to get frustrated with creative projects like this if your first efforts don't produce the amazing results you imagined. Don't give up. That only leads to the dark side...
Before I started this project I knew I would be splitting my construction time up in 3 ways. First I would be researching construction techniques and materials. This research would lead me to the second phase of construction: Experimentation. I'm no expert. I've done a fair amount of model/prop building, painting, etc and I'm only an amateur at sewing. I needed to test the new materials and methods I was putting to use. I needed to try my hand at things and learn techniques. I couldn't think that I could do it all right and perfect the first time around. That would only waste time and money. After experimenting I could begin phase three: Full on construction. The process wasn't linear though. It's more like a spiral development. You learn a little. Try something. And build.
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