Articulated fallen angel wings like Castiels

Many years ago my wife, then my girlfriend, started watching supernatural.  She loves Ghost stories.  Well I did what any man would do and teased her for it...  For about 3 years, then I got hooked on it too...  Damn it.
Once day I found myself having a conversation with a super cool lady that loved supernatural and would take her Niece from college with her to conventions all over the states.  She mentioned something about how cool it would be to have a set of wings from the fallen angel  Cas' to give her Niece for cosplay.  Well my mind immediately yelled "OMG DOOO EEEET!"  at me.  To which I responded by telling her I'd be happy to build awesome articulated wings for her Niece, and so we begin.

The wings had to be VERY light and very strong, so I decided to use aluminum to build the harness and the skeleton for the wings.

The joints connecting the wings to the harness had to be reinforced with steel to allow for articulation. So I built double sided flanges to house joint structure.

Simple finger welds hold both sides of the flange.

After the flanges are in place and ground smooth I had a working home for my wing joints that would allow for all kinds of articulation.

The shoulder joints were braced and fitted so they would allow the wings to rotate up and down and back and forth.

The wing skeleton was a 1/4in by 4ft aluminum rod, shaped with custom built equipment and welded in place.

This is the harness plate upside down. The two aluminum plates have been cut and welded that will eventually become the shoulder harnesses.

Semi-transparent black cloth will be used to cover the wings to help give them a solid undertone.

Both wings covered. You can see how much better I got on the second one. The flourish will cover them both though.

Finishing the harness up. The shoulder bars have been bent into shape, covered in padding, then duct tape was used to hold the padding on, and finally some of the black cloth was hemmed and attached to them.

Pre-shredding the cloth that will be the flourish for the wings. This was by far the hardest part. About 40 yards of this had to be made by hand, with a custom made brush 1 inch wide... It was harsh.

Trying on her wings the night before heading out to a convention. The wings swivel forward and back giving them a killer natural movement. Ill get photos of the whole outfit and add them as soon as I can.