Eric Allan Hall has been working on his Borg costume since 1993. Over the years, he’s added more and more to it and won several costume contests along the way. StarTrek.com invited him to share his method with his fellow Trekkies.
While the article doesn’t contain comprehensive, step-by-step instructions for building a Borg costume, Hall goes through each section of his award-winning outfit and details what it’s made of and how he goes about building and refining it.
Some of the basic things Hall writes you need are:
- Black cotton pants and a turtleneck for your base layer.
- Black and white spray paint to give your costume a consistent color.
- Children’s baseball helmet for headgear.
- Acrylic paint and model paintbrush for detailed work.
- Sewing supplies like needles and upholstery thread.
- Black tubing and padding material.
- Glow sticks and LED lights.
Read Eric Allan Hall’s full guide on how to build a budget Borg costume at StarTrek.com.
Once you’ve got those things, you’re ready to add your own personal flair to your Borg outfit. Hall’s costume includes things like a neck fan, battery-operated plasma disc, hologram sticker of a spring, voice modulator, leaf blower tube, snow boot, toys, and more odds and ends that Hall has collected over the years.
You can get parts for your Borg costume pretty much anywhere, so long as you keep your eyes open. Hall finds his costume components in places like yard sales, joke shops, fabric stores, surplus outlets, thrift stores, Halloween supply shops, and electronics stores, just to name a few.
Being a Borg isn’t the only thing Hall is known for. FanX Salt Lake inducted him into their cosplay Hall of Fame in 2015 for his costumes of Star Trek’s Lt. Commander Data, Superman, Harry Potter’s Remus Lupin, X-Men’s Nightcrawler, The Joker, Red Skull, Green Lantern, Mr. Incredible, and more. His Instagram is filled to the brim with cosplay images that show his incredible devotion to the hobby.
He also previously shared his child assimilation tactics on StarTrek.com back in 2020. And in 2017, he penned a piece about how to get the most out of a comic convention. Additionally, Hall is a member of HEROIC, a non-profit organization of cosplayers that performs for charity events.
Keep in mind that Hall’s outfit is 30 years in the making, so you shouldn’t expect your 2020s costume to have the refinement that he does in its first year out.