I used natural muslin for the clothing and brown fleece for the robe/cloak. For a pattern, I winged it for the robe. I had him lay on the fold of the fleece and cut a loose robe shape with bell sleeves for the back piece. I used that to make the two front pieces. This gives a seam on the top of the sleeve; you could do it a different way if you really wanted to avoid that. For the hood, I just took about a 12 inch wide by 24 inch long piece of fleece folded in half. I sewed a seam up the back and attached it to the robe. All of the edges are finished with simple serging. Nothing fancy.
For the muslin, I used an uncut pattern I had in my stash, Butterick 5565. It's a children's scrubs pattern. The pants were used as is. I used the basic scrub top pattern, except I made the sleeves long and finished the neck diferrently. I made a faux wrap-around band that goes around the neck. Then you have the tabards and the obi (the shouder things and the wrap around the waist). The tabbards are simply long pieces of fabric sewed in half and turned and placed over the shoulders. The obi is a wider similar piece, but then I pressed the front into folds to make it appear to have layers. Wrap it around the waist over the tabards. Keep it closed with hook and loop tape, snaps, or a safety pin. Safety pins are also handy for keeping the tabards on the shoulders. Over the obi is a normal belt with the buckle placed in back that he could hang his lightsaber from. The funniest thing is that he is wearing my brown boots. They were a bit large, but they worked for our purpose. He had no shame in telling people they were mine. ;)
I'm glad he liked the final result, seeing as how I started on it the day before Halloween. There are many sites out there that can give you hints and close-up pictures of Jedis if you need them. Happy Halloween!
