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Submitted By:
Esotek
The descriptions and pictures of the following costumes were supplied by the designers, although I've edited them a bit.
If anyone else has a costume they'd like posted here, email me the details and images.
Esotek@Tron-Sector.com
TRON by IronWulf
I started out with the one element I knew would take me the longest, the helmet. I should mention that any time I have to work on a helmet or loose-fitting full-head mask, I use a bust that I created just for this purpose.
 The bust began with a standard life-mask made with plaster impregnated bandages available at craft and medical supply stores. As you might have guessed, I sat for about half an hour with pieces of drinking straw up my nose, while my mother wrapped my Vaseline coated face in plaster bandage. After the bandages had set, the cast was carefully removed and the breathing holes patched with small pieces of bandage, and more Vaseline applied to the inner surface of the mold. I then poured plaster of paris into the life-mask, let it set, and carefully removed the finished life-mask. I sculpted a bust around the life-mask, all the way down to the beginning of the shoulders. This involved taking measurements from my head and comparing the bust to them, until the basic geometric requirements had been met, and then using a bit of finesse to make everything fit together properly.
The original helmets used for the film were a style of hockey helmet in use at the time, extended slightly at the back to hide the hairline. Since I couldn't lay my hands on one on short notice, I began sculpting it in oil-based clay over my custom-made bust. I used paper templates as a guide to insure that the sculpture maintained it's goemetric qualities, and to make sure the side details would remain symmetrical. Finally, a plaster mold was made, and a positive cast made with a cellulose-based material called Celastic. If I had it to do over, I would have cast it in polyester resin and fiberglass, since Celastic must be dissolved in acetone (which is relatively toxic if not handled properly), and must be sanded and filled before being painted and finished. Alternately, I could have broken the original up into sections and vacu-formed it, but we live and learn! The finished positive, after having been filled and sanded, was painted with a cheap, white, oil-based primer (which has yellowed with age - next time I'll use acrylics), and detailed with the circuit pattern. Lastly, the interior was padded to make it more comfortable to wear.
In the images above you see some of the painted circuitry work being done by hand. I could have masked all of this off, but it was faster to do it freehand. The disc, is a glow-in-the-dark frisbee with most of the surface detail sanded off, and new stripes scribed in and painted flourescent blue. The shoulder and arm guards are formed from Celastic in much the same way as the helmet, and attatched to the leotard with small pieces of elastic glued to the pieces and sewn to the costume body.
YORI by IronWulf
Visit IronWulf's TRON costume page for more pics and info.
TRON by BaumSquad
 First thing to find was some armor. For this, I went to Play It Again Sports (the BEST place to get Halloween gear IMHO) Anyway, I picked up some Hockey gear, which looks amazingly similar to Tron gear. Some hockey helmets look almost identical to the Tron helmets. I found a GREAT helmet used for pretty darn cheap. Then I needed a chest plate because<
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