whenanangelfalls:Revenge of the Sith | Behind the Scenes | You got a suit? Suit up! The Darth Vader
whenanangelfalls:Revenge of the Sith | Behind the Scenes | You got a suit? Suit up! The Darth Vader mask for Revenge of the Sith was rebuilt from scratch, using a new digital design to computer-lathe the base master, from which molds were made to cast the on-screen costume masks. The resulting masks are, for the first time in Star Wars history, truly symmetrical. “The breath? The breath! I got them to… the guy who made the costume (Ivo Coveney), I got him to make a little voice box, or asked him if he could and he was kind enough to oblige. He made a little breathing apparatus, so I could flip a switch and I would get the full effect of the Darth Vader breathing when I walked on the set for the first time.” - Hayden ChristensenOn September 1, 2003, late in the afternoon, the Episode III production descended on Stage 4, where the minimal set of the rehabilitation center was built with just a table on a raised platform. With a crowd gathering to witness Darth Vader’s return and Hayden Christensen getting dressed in a specially set-up wardrobe tent next to the set which had been constructed as a makeshift dressing room because Hayden in his Vader costume couldn’t walk very far. Everything was going according to plan when Lucas realized that they never thought to make cuffs for the ankles. Using bits of a nearby sprinkler system, Ivo Coveney (the Costume Props Supervisor) was able to deliver the ankle cuffs in 20 minutes, just in time for filming. After arriving on set to loud applause, Hayden and the crew filmed the transformation. In one of the takes, the face plate of the mask was lowered onto Hayden’s face by a crew member using a pole. -- source link