This is the in progress detail for my Giger Alien costume. The process for creating each piece is detailed below.

There is a YouTube video about this, and you can also discuss this project in my forums.

Head

The head for the Alien suit was sculpted in clay, moulded in latex - it's not the best thing to use but it is cheap for large casts, and cast in Jesmonite based fiberglass. This article includes pictures of the entire process.

Torso

The torso was sculpted in a variety of household items as well as some oil based clay. This was moulded in plaster and cast with black pigmented liquid latex. This article includes pictures of the entire process.

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Back-tentacles

Again, these were sculpted in clay with some details made from curtain rings, then they were cast in latex and foam filled. This article includes pictures of the entire process.

Breast-bone

This was another clay sculpt, a plaster mould, and latex cast - this piece was made solid with velcro straps embedded into the latex so it could tie the front of the ribcage together. The cast also had a piece of aluminium wire inside to hold it straight. This article includes pictures of the entire process.