My husband is currently building his 3rd costume - Kylo Ren, here's copied from his build blog:
(Jan 2016) So a new era of Star Wars has begun and what the hell, why not build a new cosy hey?
No doubt at some point I'll be building a new FO whitearmour trooper of some kind from TFA.... or even one of the new pilots, they look pretty cool. But, for now I thought I'd give Kylo a crack because I like the character (nothing wrong with a little tanty throwing here-and-there), he has soft parts mostly, can sew most of it myself (when I say 'myself' I really mean Lowina, using the sewing machine I bought her for her birthday , I like the all-black look (I am a Blackman after all), and because I have never really built a cosy of a 'main character' before.
So here goes.
BIG shout-out to Tom Campbell (TDK Props, check him out on Facebook) (Update April 2016: TDK has now teamed up with Corrie Mills to become 'TCM Industries', check them out on FB) who, although only just joined KFS late last year, has been a life saver and wealth of knowledge when it came to starting my Kylo build and coming up with lots of good ideas, tips and hints for doing things generally. He also does some sweet 3D printing. Cheers mate
So it all started in a city not so far away after chatting with TDK about being interested in building a Kylo and he called me one day and said there were some Black Series Kylo buckets in Toys'R'Us and asked 'would you like one?' and I said 'yes' and next thing you know I'm walking around the house staring at myself in the mirror wearing my new Kylo bucket. Following suggestions on the Sith Lord Detachment (no idea why Kylo belongs to that detachment, but anyway...) and people in the Knights of Ren Facebook page (great source of info), there were a few mods that needed to happen to the bucket. Sealing up the join around the outside centre area, adding a new mesh style visor, repainting, plugging up some holes, drilling out some plastic bits, etc, etc....