Darth Revan Costume: Mask, Armor, Robes and Budget Tiers

A Darth Revan costume is a black hood and cape, a weathered mask in dark grey and rust red, rigid ridged armour, a belt with a large O-ring, a deep red drape, a black split skirt and boots, plus an optional saber [1]. The mask and armour are the hard parts. Revan is mainly a Legends character, so there is no film costume to copy, only the Knights of the Old Republic design [3][4][8]. Below: each piece, materials, three budget tiers, what “501st accurate” means for Revan, and a short Darth Malak section. The saber has its own page, Darth Revan’s lightsaber.

This is an informational guide. Star Wars and its characters belong to Lucasfilm and Disney, and this site shows no film stills or logos.

Last checked: 2026-11-12.

Quick answers

• Status: Legends, with one canon mention of a Sith legion named after Revan [3].
• Hardest pieces: the mask and the rigid armour [1].
• Boxed set: one licensed set found at $124.99 as of November 2026, without mask or boots [9].
• Club reference: the 501st Legion Costume Reference Library lists Darth Revan for both Knights of the Old Republic games [1].
• Saber: red for the first game, and one red plus one purple for the second [1].

Is a Darth Revan costume canon or Legends

Canon is the continuity Lucasfilm treats as current. Legends is the label for licensed stories from before the April 2014 reset. Revan was created for the 2003 game Knights of the Old Republic, which is Legends [3][4]. Current canon names Revan once: a 2019 reference book says the Sith Eternal army had a Revan Legion [3]. Wookieepedia also notes that Revan was meant to appear in a Clone Wars episode, but the scene was cut [3].

So no canon source defines the outfit. The look comes from the games and from licensed reference books [1][4]. Wikipedia credits concept art director John Gallagher with the masked design, following a brief from James Ohlen, and says Gallagher drew on Mandalorian and Boba Fett imagery [8]. Wikipedia also says the masked Sith look is separate from the customisable player character [8].

For other costumes with the same status question, see the character costumes guide.

Revan cosplay: the parts at a glance

The 501st Legion Costume Reference Library lists the pieces below. It is a visual guide for judges, not a construction manual [1]. The page marks some details as “Level two”, which are optional [1].

The Darth Revan mask

The reference describes a mask that reaches the top of the head and ends no more than an inch below the chin. The front is dark grey and rust red with heavy weathering. The eye slit has a lens dark enough to hide the eyes, and the chin carries two prongs with hardware [1]. Black side panels like the game render are optional [1].

Wookieepedia says Revan wore a trademark mask and robes through both the Mandalorian Wars and the Jedi Civil War, and that the Foundry battle later left a vertical scar across the left half of the mask [4]. It also describes an earlier moment in the Revanchist story when he put on a fallen Mandalorian’s mask [4]. Those are Legends details.

Two rejections matter before you spend money. The 501st reference does not accept the flat chin SWTOR-style mask, and it names Darth Revan costumes sold by a brand called Cosplay Sky as unaccepted [1].

If you buy a boxed helmet, read the vision line first. The licensed Jazwares Revan helmet listing at Halloween Costumes says “limited vision through the black vision port”, and a Q&A answer calls it more restrictive than a Mandalorian style visor [10]. It is one size with an inside sizing band [10]. The reference itself asks for a lens dark enough to hide the eyes, so any accurate mask limits your view [1]. Expect to move carefully in crowded halls.

Darth Revan robes, hood and cape

The cape and hood are heavy black fabric [1]. The hood is full, and the lower front tucks under the chest armour. The capelet hooks to the cuirass with four silver rings, two larger and two smaller. Its shoulders are gathered and draped, not pleated [1]. The cape below has knife pleats pointing toward the centre [1].

Under it, the reference lists a black balaclava and a black long sleeved shirt with a high collar and horizontal piping across the chest [1]. Gloves are plain black leather or fabric, long enough to cover wrist skin and tucked under the vambraces [1].

Wookieepedia says the Legends robes, made by the Star Forge in the game story, are predominantly black and red [5]. The same page says the dark side path in the game gives the player robes very similar to the Sith original [5].

If you only want the cloak and layers, the Jedi robe guide covers fabric and sizing, and the Jedi costume guide covers the base outfit.

Darth Revan armor: cuirass, vambraces and hand plates

The reference calls the cuirass rigid, with ridge patterns matching the game references and a raised black panel on each side. Each panel carries two loops for the capelet rings [1]. A black leather or vinyl bridge with close horizontal ribbing and silver paint weathering sits about four inches tall [1]. The abdominal armour has two arching black shapes at the hips and six two inch rings, matched by six rings on the kidney armour [1]. The back armour continues the front design so the torso is fully enclosed [1].

Vambraces are rigid, seamless and one piece per forearm, from wrist to just below the elbow, with a ridge up the inside seam [1]. Hand plates are rigid, with parallel horizontal ridges across the centre [1]. The metal sheen is bronze, copper or antique gold [1].

The reference does not list shoulder armour [1]. A padded chest piece, such as the one in the Halloween Costumes set, is not the rigid cuirass the reference asks for [1][9].

Belt, sash, skirt and boots

The belt does not go around the waist. It hangs from side straps in front of the abdominal armour and slopes to a large front O-ring. The straps are black, leather-like and weathered with silver paint, and there are silver or grey bands and four smaller O-rings [1]. A black sash attaches to the O-ring at both ends and hangs loose behind the thighs. The deep red drape hangs vertically behind the O-ring and does not pass through it [1].

The skirt is black, reaches the ankles, and has a vertical split at front and back centre with large box pleats [1]. The reference rejects hakama pants for the skirt [1]. Trousers are black with no decoration. Boots are black or medium to dark grey, with a wide strap across the foot, a low heel and no visible laces [1].

For clipping a hilt to a belt like this, read belt clips and holsters.

Materials for a Revan cosplay build

The reference names black fabric, leather or vinyl for most pieces, dark grey and rust red for the mask front, bronze, copper or antique gold for the armour sheen, silver for rings and weathering paint, reddish-brown for the back armour strip, and deep red for the drape [1].

For masks, a foam guide from Feroca recommends 5 mm high density EVA foam, two layers where you need body such as the forehead and nose, and 2 mm for fine details [12]. It uses contact cement on both surfaces, seals the foam with diluted white glue at about 1:1 or a flexible foam primer, then paints with acrylic or spray paint. Dry brushing is its suggested way to weather the surface [12]. It also suggests an extra foam strip inside joints for heavy convention use [12].

That guide covers masks, not armour. The reference asks for rigid armour [1], and I found no source saying foam passes that rule, so check with your local 501st unit before building the cuirass in foam. For printing a saber hilt instead of buying one, see the 3D printed hilt guide.

Darth Revan costume budget tiers

Prices below were read on the pages cited and can change.

Tiers 1 and 2 are party costumes, not reference builds. A mixed route is also open: buy the robe set, then swap the mask, armour and belt one piece at a time against the reference [1][9].

501st accurate Darth Revan: what it means

The 501st Legion keeps a Costume Reference Library with a written guide per costume, and the lightsaber cosplay costume guide explains how that library and club judging work. For Revan, the library page covers both Knights of the Old Republic games and treats the lightsaber as optional [1].

Saber rules from the page: for the first game, one saber with a red blade if lit. For the second game, two sabers, one red and one purple. Hilts must match the game file hilt or the Star Wars Encyclopedia entry, and SWTOR-style hilts are rejected [1]. See red lightsaber and purple lightsaber for blade choices, and dueling clubs if you also fight in it.

Darth Malak costume

Wookieepedia files Darth Malak under Legends, as Revan’s apprentice in Knights of the Old Republic [6]. It says that as a Sith Lord he wore skin-tight, red-orange body armour with a half cape of black cloth, and carried a self-built saber with a red blade [6]. His jaw was removed by a lightsaber strike from Revan, and he wore a large metal shield over his lower face with a vocabulator for speech [6]. A stub page on his saber agrees on the red blade [7].

The 501st reference for Malak is listed under Star Wars: The Old Republic and names no game version [2]. It asks for:

• a clean shaven or bald cap head, pale skin, black around the eyes and grey markings on the scalp [2]
• a matte burgundy body conforming shirt and burgundy trousers [2]
• rigid burgundy chest armour with a trim band [2]
• two separate rigid dull grey pieces for neck and jaw [2]
• a matte black cape that crosses the chest diagonally [2]
• a rigid grey belt with square decoration [2]
• leather or leather-like boots with gunmetal ankle armour and shin armour [2]

The saber is optional and grey metallic with two small red buttons [2]. The page says only the requirements marked in black must be met for membership, but the text I read does not show which items those are [2].

Malak and Revan both come from the games. For Sith characters who appear in the films, see Darth Maul’s lightsaber and Darth Vader’s lightsaber, and for a film by film list see every lightsaber by film.

Travelling with a Revan costume

The display, store and travel guide covers packing a hilt and props. For other character pages, see the lore hub.

Sources

1. 501st Legion, Costume Reference Library, Darth Revan KOTOR I and II, https://crls.501st.com/tfe/darth-revan-kotor-i-and-ii (accessed 2026-11-12)
2. 501st Legion, Costume Reference Library, Darth Malak, https://crls.501st.com/tfe/darth-malak (accessed 2026-11-12)
3. Wookieepedia, Revan (canon), https://starwars.fandom.com/wiki/Revan (read through the public API, accessed 2026-11-12)
4. Wookieepedia, Revan (Legends), https://starwars.fandom.com/wiki/Revan/Legends (accessed 2026-11-12)
5. Wookieepedia, Darth Revan’s robes, https://starwars.fandom.com/wiki/Darth_Revan%27s_robes (accessed 2026-11-12)
6. Wookieepedia, Darth Malak (Legends), https://starwars.fandom.com/wiki/Darth_Malak (accessed 2026-11-12)
7. Wookieepedia, Darth Malak’s lightsaber, https://starwars.fandom.com/wiki/Darth_Malak%27s_lightsaber (accessed 2026-11-12)
8. Wikipedia, Revan, https://en.wikipedia.org/wiki/Revan (accessed 2026-11-12)
9. Halloween Costumes, Men’s Premium Star Wars Darth Revan Costume, https://www.halloweencostumes.com/mens-premium-star-wars-darth-revan-costume.html (accessed 2026-11-12)
10. Halloween Costumes, Adult Deluxe Darth Revan Helmet, https://www.halloweencostumes.com/adult-deluxe-darth-revan-helmet.html (accessed 2026-11-12)
11. Bleeding Cool, Jazwares debuts new Star Wars Darth Revan deluxe costume, https://bleedingcool.com/collectibles/jazwares-debuts-new-star-wars-darth-revan-deluxe-costume (accessed 2026-11-12)
12. Feroca, How to make a cosplay mask from EVA foam, https://feroca.com/en/blog/cosplay/make-cosplay-mask-eva-foam (accessed 2026-11-12)