Sometimes I come across projects on The RPF that I can’t help but check in on every day to see the latest progress. I’ve been eagerly watching Kialna’s human version of Smaug the Magnificent evolve for months now, and while it’s not done just yet, there’s plenty to show off. She first posted about her idea to make a costume of the character in August of last year. She patiently waited until The Hobbit: The Desolation of Smaug was released in December so she could gather more images and adjust her sketches. The project required her to try new skills like making a cast of her arm so she could sculpt dragon claws onto her fingers and make gloves from them. She made the base of the head from what appears to be foam core boards and filled it with expanding foam which she sculpted into shape.
Though she doesn’t discuss exact materials and how-tos for every step of the build, she has posted enough pictures and comments that you can learn a lot from her endeavors. You can keep up with the latest developments and photos over at The RPF. I highly recommend checking this thread out because it involves multiple materials, has some examples of problem-solving construction issues, it shows how much of a commitment a big cosplay project can be, and it also illustrates how a costume’s design can change over time.