For the suit I got a red, full-face suit from superfansuits.com (totally awesome suits for anything like this sort of thing!) Then I bought a Captain America mask, had AMDarkness sand down and fill in the "A" so it was smooth, trimmed it off some then...

I do more costumes than just Star Wars; one of the ones I'm currently working on is "Severus Snape" from the "Harry Potter" books and movies. This is a much easier costume than many others I've done because I can simply buy the jacket, pants and wand....