The Field Repair Kit
The essential repair kit that fits in a small bag: safety pins in every size, double-sided fabric tape (Fashion Tape or similar), a small hot glue gun with 5–6 sticks, thread in your costume's main colours with a needle already threaded and taped in place (saves time under pressure), super glue, E6000 for anything structural, a small pair of scissors, and any small replacement parts specific to your costume — clasps, buttons, snaps.
Common Failures
Broken zip: if the zip pull breaks, use a safety pin through the zip hole as a temporary pull. If the zip separates at the bottom, safety pins up the seam as a temporary fix. Detached armour piece: hot glue for immediate reattachment; E6000 for a more permanent field repair. Torn seam: if accessible, hand-stitch with the pre-threaded needle; if not, use fabric tape on the inside. Lost button/clasp: safety pin in the same location; replace properly after the event.
Blister Prevention and Treatment
Cosplay shoes are often worn for the first time at conventions — a guaranteed blister situation. Moleskin applied to pressure points before blister formation prevents them; moleskin with a hole cut out to fit around an existing blister relieves pressure. Change into comfortable shoes for any long walking sections and switch back to costume shoes for photo opportunities.
When to Retire the Costume
If a costume fails beyond the ability of field repair and the failure affects comfort or safety — sharp wire poking through fabric, structural failure that creates a falling hazard — change into a backup costume rather than suffering through the day. The convention is more important than the specific costume.