Halloween costume

I'm going to be in my cities Halloween parade, with a group that is all going as different Lord of the Rings costumes, in an effort to raise money for charity. Now, I've been assigned to be an orc, although I'm doing an Uruk-Hai, because orcs are lame. Anyway, I'm going to cut the sword out of a 4x6, and hopefully get a nice bevel cut with my crappy table saw. I'll paint it with a couple coats of paint, and get a nice weathered look going on. That's the easy part. I'm still working on a design for the armor, especially the helmet. I was hoping someone might be able to give me some advice, because I don't have time to make anything out of metal, and I still want it to look good in the end. I was thinking of making most of the armor out of craft foam, and painting it with shoe polish and craft glue for a metallic shine. The problem is, I don't have any templates to work with, and I'm running out of ideas. My paper mache breastplate was a complete disaster, so i'm straying away from making anything out of that.

Is there anyone who could offer me some advice? This is going to take most of my free time until Halloween, so I want to make it nice. I really appreciate any help.

I would help if I knew ONE thing about Lord of the Rings.

sorry i cant help ya at all i hate that move so much

if youi play paintball you could use one of those or just make one of those...

uhmm for the armor... search on google.....

Ya, I did search on google. I know how it looks like, that's not the problem. I'm just hoping for some advice regarding the making of the costume in general. You don't even need to know anything about the movies, but if you make your own costumes, then I could use some advice.

You could drop by an SCA event (http://www.sca.org) and look at what kind of things they have - if not buy some armor at least get some ideas.

There is one in Ohio the 22nd - http://cleftlands.cwru.edu/fun.html

They usually have a lot of vendors selling metalwork and leatherwork, as well as people in full medieval armor and garb. For instance, I saw that the Uruk-Hai usually wear chainmail. Making chainmail is a looong process, so you might as well buy it. It can be cheap (won't stop anything) as it will just be for a costume. Some of them get way tooo far in to it, but it is fun none the less.

That's a good idea, but i'm not quite THAT serious about this costume. I mean, it is just a costume. Plus, I don't have time to go to that, although I only live an hour away. It's just that by the time I that is held, I need to have my costume just about finished.

Here's an update for anyone who cares:
I started work on the sword tonight. I used a piece of Brazilian wood that I pulled for a used pallet that I wound at work. It is surprisingly good quality, although it is too narrow to make the whole sword from one piece. I instead cut the main shaft of the blade from one piece, and cut the spike from another and screwed them together. I used my crappy $25 garage sale table saw to cut the top and bottom bevel. I decided to save myself some time on the spike, and grind most of the extra wood off with a grinder. That was a mistake. I didn’t have a wood blade, so I used my metal grinding blade; it got so hot that my entire basement was filled with smoke, and I think the wood even caught fire for a second. I do think I saved myself some time though. I cut the handle out with a jig saw, and glued two very thin stripes of wood to the side to make it a little more round in anticipation of the leather I’m going to wrap it with. I plan on doing most of the sanding tomorrow, and hopefully making it to the Home Depot so I can buy some spray paint. I'll try to post some pics of it tomorrow if anyone wants me to.

Well I have been wearing the same costume and mask ever since I born.... and believe me is not pretty lol

This link might be helpful to you; http://www.halloween-website.com/costumes.htm

I sanded down my sword for about half an hour today, and it's looking quite nice. I'm going to sand it with a finer grit tomorrow, and then spray it. I have three colors of paint: black, grey and an orange-red color. I was planning to put the red on first, then the grey over that for my sword. I did a test piece tonight with all six color combos, but I can't see it till tomorrow when it dries. What do you think would look the best?
I met with the leader or this thing tonight, and I found out that my whole outfit has to be done by Monday. Yikes. So I have to work fast. I also found out that the weapons we will use for the parade will just be 2x4s with a bit cut out and painted black. I guess that makes since, so we don't break our nice swords. I'll just use mine for a party I'm going to. I was unable to find any sort of mask at my local Halloween shop, so I am either going with face paint, or someone said he had a generic "scary guy" mask. This is quickly turning bad.
Anyway, I do have a couple pics of my unpainted sword. I'll just post one for now. I can always post more if you want. It's not that great of a pic, and you can see my Elmer’s glue + saw dust filler I have yet to sand. Ya, I kind of over did it with the grinder.