I made a Crimson Cobra Commander costume for this year's G.I. Joe con with the help of my girlfriend. I mastered button-holing and making epic hand poses.
For the hood, I sculpted an under mask onto a cement copy of my head I have lying around, cast it in resin, drilled little holes, and hand sewed the fabric around the eyes into it. It stayed on really nicely and I didn't have to try to look angry.