Tested.com’s Adam Savage has a passion for all things making and cosplay. He regularly goes incognito in costumes at conventions, and one of the costumes he’s worn is Chewbacca from Star Wars. Tom Spina of Regal Robot helped Savage with the Wookiee mask; it had to be both wearable and look like a replica from the films. It took a team to replicate Chewie’s mask, and in the above video, Tom walks through the entire process of making it. Under that lovingly combed fur is a fiberglass shell, toggles to operate the lips, and more.
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