I was the Elephant man this Halloween. Made the costume out of bolts of fabric. No experience there, save some sewing, and I think it turned out well. Tried to mimic the David Lynch movie costume (on budget in a weekend.) Hood material was too stiff.
Almost a year ago I dressed as Dead (from the black metal band Mayhem) for dead-rock-star day at work. Good excuse to learn to do grease makeup and how to work a wig. Turned out pretty well I think.