My son (age 8 when I made this costume) really likes the Star Wars® movies.  He asked me to make him a Star Wars® Halloween costume.  I found a website called Studio Creations.  They have a complete guide on how to make an authentic looking Tusken Raider costume.  They also have a blow molded mask that we purchased from them to get the basic shape of the head.  The directions are really good but I made quite a few modifications to my son's costume.  Why?  To keep the costs down.

Here is what I did different on his costume:

1. The nose was made of clay.  It was the type of clay you can buy at a craft store, mold it yourself, and bake in the oven to harden it. 
2. The points that come out of the head were bolts.  I sawed off the threads at the end of the bolts and ground them down with a stone grinding tool.  I then glued the bolt heads to washers to make a base that could be easily glued to the head.
3. The tusks that stick out from the face below the eyes were made of two black pens.  I used only half of the pens and glued 9MM casing shells onto the pens to give it the silver looking ends.
4. We chose to not put on a respirator.  We thought the costume looked good enough without it.
5. Instead of a Gaffi stick my son used his Star Wars® laser gun as the weapon.
6. We did not match the color of the clothing exactly and bought what was on sale.

Tusken Raider Costume

We Designed Our Own Robe.

We Used a Store Bought Laser Gun Instead of the Gaffi Stick.