This costume was bought! The helmet however, is made entirely by Sheila. It is 4 layers of ultralight sculpy that was molded into shape and baked. Each layer was attached with epoxy glue, including the horn, after it was baked. It attaches to Sylar's head via an elastic band that is then hid beneath his hair. It was painted with a white primer, and left matte to better represent 'bones' for the hollow mask.
Instead of using black paint for the 'hollow hole' we decided to use a small circular mirror, so the reflection gave off the illusion of being hollow. The sword is actually a real sword, with a new tsuba (made from sculpy to match Ulquiorra's) slipped onto the blade and teal ribbon wrapped around the hilt.