04 Dec 2017 10:28 AM +00:00 UTC

Tested: The Painstaking Detail That Goes Into Making The Perfect Chewbacca Mask

Mythbuster’s Adam Savage is a huge cosplay fanatic, and his show Tested covers a lot of ground when it comes to making specific costumes and props. Savage went above and beyond when it came to putting together his Chewbacca outfit, and a new video details just exactly how he got it right.

Check it out:

What's underneath all that Wookiee fur? We visit Tom Spina Designs, the workshop where Adam's beautiful Chewbacca mask was crafted, to dive deep into the mask-making process. Adam and Tom walk through the many parts of Chewbacca, going over little-known details about how the original mask was designed and fabricated by Stuart Freeborn for Star Wars.


I have to say, though Chewbacca has been cosplayed time and time again at cons, I’ve rarely seen him done just right. It’s cool how the video covers common mistakes when it comes to making Chewie look like he did in the movie. You’ll also love all the details that come into Savage’s Chewbacca head alone.

The video also gives us a look at Chewbacca’s head without the fur, and I’ve never noticed that his mouth is “extra snarly” on one side. I kind of wish we also got to see the mechanism that syncs the mask’s mouth with the wearer.


Han Solo may be gone, but Chewbacca comes back in Star Wars: The Last Jedi which comes out Dec. 15.

See Also: Star Wars: The Last Jedi Featurette Gives Us A Look At The Cast And Their Combat Training