Shawn didn't decide he wanted a costume until a week before the premiere, so the Gandalf costume was thrown together in about 5 days. It turned out really well, considering.
I made the robe from a loose-woven grey fabric that Mela found in the $1 bin at Wal-Mart. I used Simplicity pattern 9887 as a guide, making the wizard's robe but closing it up the front. The big, rectangular sleeves I drafted myself.
The cloak was also made using Simplicity 9887, but leaving off the hood. It's made out of grey sweatshirt fleece.
The belt was a yard and a half of cording that Mela and I bought, dyed brown, and attached a silver buckle too. Worked quite well, and cost us less than $5 all together.
The hat was made from a light blue knit, interfaced to make it stiffer, using Simplicity 9887 again.
The beard is a discount Santa beard spray-painted slightly grey. It was the best we could do on short notice.
It's the props that really pull this costume together, I think. The pipe and staff were made by Shawn's wife Melanie, using a pole, a coat hanger, brown paper, masking tape and spray paint. She did an INCREDIBLE job...especially considering that her right hand was in a cast at the time.
That's Melanie with him, by the way, looking lovely as Arwen.