Cal Kestis Cosplay DIY Guide: How to Make Your Own

Cal Kestis cosplay

Star Wars Jedi: Survivor released to largely positive reviews. Despite performance issues across all systems, stellar gameplay and an action-packed story shone through. Cal Kestis has officially cemented himself as a fan favorite amongst the next-generation Star Wars cast. So much so that it appears increasingly likely that Kestis will appear in his own live-action Disney+ series. Perhaps even alongside Ewan Mgregor’s Obi-Wan.

In recognition of Cal Kestis’ enduring popularity, we want to look at how you can recreate your own cosplay for Star Wars Jedi.

Following the release of the original game, Kestis remains of the few serving Jedi. He is also one in a very exclusive list of Jedi to survive an encounter with Darth Vader. That’s a fairly concrete argument in itself for putting him and Obi-Wan together on the small screen, don’t you think?

We’re getting ahead of ourselves! For now, here is everything you need to know to create your own Cal Kestis cosplay:

More Star Wars costume guides:

Who is Cal Kestis?

Cal Kestis is the lead protagonist of Star Wars Jedi: Fallen Order, which was released in 2019. Cal is a former Jedi Padawan who survived Order 66, after the Emperor ordered the clones to exterminate all Jedi. He goes into hiding and works as a scavenger until he is discovered by the Empire and forced to go on the run.

With the help of a crew of allies, Cal embarks on a quest to restore the Jedi Order while also confronting his past and dealing with his own trauma.

What color is Cal Kestis’s lightsaber?

Cal Kestis has a blue lightsaber according to the official canon. While players are free to customize the playable character’s lightsaber with a number of color options, the promotional material for Star Wars: Fallen Jedi features Kestis with a blue lightsaber.

This is his second lightsaber but the first one that he created himself when he went to Ilum after receiving Jedi master Jaro Tapal’s damaged lightsaber.

Cal Kestis has a new lightsaber in Jedi: Survivor. Once again, the canon color is blue but players are free to choose from an array of options to suit their own style.

Blue lightsabers are the most prominent standard in Star Wars lore and are typically used to show the wielder is a Jedi Guardian: a Jedi who is highly skilled in physical combat. As opposed to green lightsabers yielded by the likes of Yoda or Qui-Gon Jinn, signifying a particularly strong affinity with the force. Or purple, signifying that you’re a bad motherf****r.

Cal Kestis cosplay

The Base

Let’s start with the easiest part first. the base of Cal Kestis’s outfit starts with a simple shirt and trouser combination. The shirt is dark blue and should be rolled it up at the sleeves. The trousers are a dark grey/green and feature added protection around the knees. Much like motorcycle pants, which achieve a very similar style quickly and effectively.

The poncho and armor

A major component of the Cal Kestis cosplay is his signature poncho and leather shoulder armor. Kestis wears a military-style tactical poncho in dark navy blue. He also has both arm and body lengths cut shorter than your average poncho, following just below the shoulders and waist respectively. That means you will likely need to do some light modification to whatever poncho you go for.

Kestis wears a leather vest over his shoulders for added protection. This will likely take some crafting as the style is quite specific. We recommend using full-grain leather overlaid on dark grey suede or similar. Otherwise, you can find a full shoulder arm and weapon sling replica from aliexpress that does an admirable job.

The finishing touches

Cal Kestis wear a distinct leather shoulder strap with space for ammunition. What looks like a leather gun sling for a blaster – or rifle in our galaxy. If you would prefer to purchase a readymade gun sling, we recommend this buffalo hide leather sling from Raiseek.

Finishing touches include a leather wrist gauntlet and leather safety glove.

Cal Kestis cosplay lightsaber

The lightsaber

As mentioned above, Kestis’s lightsaber is canonically blue. If you are looking for a genuine Cal Kestis lightsaber replica, the official prop designer Galaxy’s Edge has a stunning hilt model of his first (damaged) lightsaber. Complete with a custom engraved stand (or as a standalone lightsaber hilt) and incredible attention to detail.

You can combine this with the Galaxy’s Edge lightsaber blade (capable of emitting multiple blade colors) for the best Cal Kestis cosplay on this side of the galaxy.


With the release of Jedi: Survivor and a host of Disney-related projects in the works, we have a feeling we’re going to be seeing a lot more from this part of the canon. The Cal Kestis and Obi-Wan crossover is set to be the character’s first foray onto our TV screens with an upcoming Cal Kestis live-action series also reportedly in the works.

All this is a testament to the character’s ongoing and ever-increasing popularity. Long may it last!

For more sci-fi cosplay inspiration, check out our article on Dune’s iconic stillsuit design. Set to make its return to the big screen later this year, Dune costumes are sure to be a popular option for the foreseeable future.