Final Fantasy XII
Ashe Costume and Sword
I made the pattern for the suit up from scratch since it didn't resemble any existing pieces of clothing. The denim bustier worn under the suit was heavily boned and the miniskirt was made from vinyl.
All of the armor was made using my foam and styrene method. (You can find a picture tutorial on the making of the armor here at this link.)
The sword was a huge undertaking--I built it by hotgluing styrene over a shape that I had carved from styrofoam and wired together. It had a PVC handle.