The Cutest Couple in the 'Verse: Simon and Kaylee Costume build log.

HeroOfThePeople

New Member
您好,托制造商和Browncoats的! (Hello prop makers and Browncoats!)

With Halloween fast approaching my fiance and I hadn't yet selected our costumes. With both our time and budget constrained by wedding planning expenses and activities we wanted something relatively low budget and easy. Last Wednesday my beautiful bride to be suggested Simon and Kaylee, "Yes! Done! I concur!" was my enthusiastic reply. We spent a couple days thinking and on Friday 10/4 I got started in earnest.

Our first Halloween event is on the 26th, so that's 23 days in total (including the day of the event) to complete both costumes, 20 days remaining as of this writing. In this thread I'll log my progress, talk about my process, and share WIP pictures, I hope you enjoy following along. I'll be doing both Simon and Kaylee as they appeared in Serenity (the pilot of the series, not the Big Damn Movie), though fortunately for the screen cap hungry costumer Simon wears the outfit several times throughout the series short run. The vest appears in Serenity, The Train Job, Jaynestown, and Ariel. The jacket appears in Serenity and Janyestown. Kaylee's coveralls are in practically every episode, though the brocade jacket is never seen again.

Day one Friday 10/4: Planning

  • [*=1]Re-watch Serenity to make observations, notes and take screen captures.
    [*=1]Because time is limited I identified the key iconic recognition elements of both costumes as well as the supplementary details and laid them out in order of priority. Simon just isn't Simon without the waistcoat and red spectacles, Kaylee must have the floral print 3/4 sleeve shirt and the coveralls (complete with patches and Chinese character embroidery). These must have's will be prioritized first in the build.
    [*=1]Additional nice to have elements in priority order: Kaylee's sky blue floral brocade mandarin collar jacket, Kaylee's Parasol, Simon's no collar or lapel black jacket, Kaylee's flip-flops, Simon's surgical apron, Simon's doctor's case.
    [*=1]Key observations: Simon's vest has a very flat front, no pockets, not especially fitted, really high neckline for a waistcoat, subtle black on blue wavy brocade front with black back. Kaylee's jacket has a rounded mandarin collar, her parasol has a lot of wear and weathering. Kaylee's coveralls drape like their mostly cotton
    [*=1]Made a trip to the fabric store for investigation & inspiration. The brocade for Simon's vest will be hard to come by, but good offerings for Kaylee's Jacket are readily available.
    [*=1]Did some pattern research looking for Kaylee's jacket.

Day two Saturday 10/5: Shopping


  • [*=1]Fabric store trip: Picked up a pattern for a Mandarin collar jacket, it will need some tweaking, but its close. Since I can't find the right Brocade for Simon's vest in time or on budget I went with a navy satin. Picked up black lining for the vest as well. Got the sky blue floral brocade for Kaylee's jacket as well as a yellow lining (the lining isn't ever clearly visible on screen but I chose the yellow as it seems to compliment the brocade, and its cheery just like Kaylee). Also got the requisite interfacing and notions.
    [*=1]Military Surplus store: Picked up an olive flight suit, would have preferred a set of mechanic's coveralls but no such luck. Fortunately this was an older one, high cotton content, no nomex. It needs to be made sleeveless and add a band around the waist in order to more closely match. Beyond the required alterations to match the costume it also needs to be tailored for fit. As my lady is 5'0" this suit is way too long, Kaylee wears the legs rolled up so no pressing need to hem them but the crotch hangs way too low. The torso needs to be shortened.

Day three Sunday 10/6: Pattern Work.


  • [*=1]Not a lot of work time today but I modified an old Buckaroo Bobbins Victorian vest pattern I had laying around to make the Simon vest. The pockets came out. The darts were made less severe. The neckline was raised. Fortunately these modifications actually make the vest simpler to make. I ended up with a four piece pattern: front, back, facing, and belt.

Tonight I hope to cut and start sewing vest. I'll update this thread with pics when I get home from the office.

Will I get done in time? Will these costume's be as shiny as I hope? Is there a power in the 'verse that can stop me? Stay tuned to find out.
 
Day 4 Monday 10/7: Cutting

  • [*=1]Not a lot of time to work today between interviewing a potential wedding vendor at a coffee shop, and cleaning the house for a potential vendor who's coming to us tomorrow only 20 minutes for costume work before I had to get some rack time so I wouldn't be a zombie at work today, but I made the most of the time I had getting the cutting mostly done for the Simon waistcoat.
    [*=1]Unfortunately I discovered bought too little lining fabric. I think I'd assumed that the fabric was on a 60" bolt when it was in fact on a 45" bolt, meaning I'm short two back pieces. I'll be picking up the additional needed fabric on the way home from work today.
    [*=1]Other than the missing lining pieces the cutting is all done

10156529793_cc0eda787a.jpg

Front piece after cutting.

10156293824_f095850b31.jpg

All of the cuts piled up at the end of the night, you can see the Blue Satin I'm going with here. Its close to the right color, obviously not the Navy and black brocade with the wavy pattern, but the Navy satin is close to the base color of the brocade, So I'm comfortable with it given this timeframe and budget.
 
Day 5 Tuesday 10/8: More cutting, pattern marking and finally putting needle and thread to fabric.

  • [*=1]Another day with not a lot of work time. Things are taking longer than I'd like and I'm having less work time than I'd expected. This worries me.
    [*=1]I picked up more vest lining material on the way home and cut the remaining back pieces.
    [*=1]Transferred pattern markings to cut pieces.
    [*=1]Started sewing the vest, sewed finished the front darts, back darts, joined the back halves together, made the vest belt (I'm waiting to add it to the vest until I figure out how I want to do the sizing adjuster), joined the vest fronts to the vest back, put the facings on the front linings and sewed the front lining darts. This leaves the the lining back darts, joining the lining back halves, attaching the lining fronts to lining back, and joining the lining to the shell. I'm hoping to get through that portion tonight.
 
Day 6 Wednesday October 9th.

  • [*=1]A pretty productive day. I was able to carve out an entire hour for costume work, during which I finished the following:
    [*=1]Placed orders for the Simon spectacles (Zenni Optical #550021 with red lenses, their site isn't link friendly.), this parasol, and the Kaylee Coverall patches.
    [*=1]Completed the vest shell by attaching the belt, finished the vest lining, pinned the lining to the shell. All that remains for the vest is to join the lining and shell, turn the garment, stitch the side seams and add buttons and holes.

Speaking of buttons, Simon's vest buttons are fabric covered shank buttons, the only ones I've found locally available are way to big (1" buttons), I haven't gone back to my screen caps to accurately determine scale but anything over 1/2" would be too big. Does anyone reading this have a line on 3/8" covered button making materials, or pre-made 3/8" covered buttons in the proper color? Thanks.

On deck for tonight is finishing the vest. Friday should be a big progress day for costumes where I start work on Modifying the coveralls. Expect new pictures tonight and more tomorrow.
 
Day 7 and Day 8 AM vest nearly done, updated pictures

  • [*=1]Vest lining joined to vest shell, turned and closed last night, took a test fit, and discovered it was too tight. There's nothing quite so frustrating as finishing a garment and discovering immediately that you have to let it out.
    [*=1]Let the vest out out for a better fit.
    [*=1]It still needs buttons, but I plan to take care of that this evening.
Here's what it looks like at this point.

10212614534_c8b2b045b0.jpg

10212709285_52f66ec4ff.jpg


This afternoon I start on the Kaylee Jumpsuit.
 
Took the weekend off from costume work. On Friday I finished the jumpsuit alterations, still waiting on the patches to arrive in the mail.

We got the parasol so work can get started on that. Next big hurdle is the Kaylee Brocade Jacket.
 
Day 11: Patches! Jacket!

  • [*=1]The Kaylee Patches arrived in the mail, so the future misses Hero started handsewing them on the coveralls.
    [*=1]Meanwhile altered the pattern for the Kaylee Brocade Jacket, drafted and cut my pattern pieces and cut my fabric. I'll start sewing the jacket tonight.
 
Back
Top