Wooh! Some replies

Thought I was going to have to go it alone.
Georgi - 'fraid there isn't much info on the Seguleh. Their culture isn't explained much but basically they dedicate their lives to battle in a way that would make a samurai look lethargic. To preserve their integrity as warriors they can challenge another seguleh even in the midst of battle with a forign invader i.e. if they see any mistake in stance or skill that could suggest weakness. The battles aren't normally fought to the death as there is no need and are normally judged, if they occur on home territory, by the higher ranks and can be interpreted as a loss if one fails to take advantage of an opening. Their fighting style is described as surgical cuts instead of stabs and slashes, similar to the stikes of dim mak. Thanks for the celtic idea, will have to see if anything jumps out at me. Didn't prefer designs from someone who read the books as they aren't really described that much.
Thanks Alyx for the well wishes and for putting your bf onto the thread
Itami - I'd say you're probably right but would argue there are a couple that could compete for that title e.g. Chronicals of the Black Company or Song of Ice and Fire, then Wheel of Time even though the writing isn't as good the plot competes. While I've been making the weapons and mask I was thinking who else and Gruntle came to mind - you should do it man, he's awesome, bet his cutlass' would be fun to make too. I thought I might try a regular Malazan like Fiddler but then started thinking about it and there are so many charcters that'd be awesome. The Rope would be pretty cool mainly for his weapon, Karsa Orlong is my next one I think - was gonna try to make the Deragoth heads and attach two chains to my belt dragging them and the face tattoo would be sweet, then there's always Dasam Ultor, Kallor, the 2nd, Iron Bars or Skinner ..... SO many. Let's not forget Coltaine who'd be my next pick if I could afford to buy that many feathers to make his coat.
Seriously though you should so go as Gruntle ..... not sure what you'd do about his soultaken/d'ivers form though : P
Thanks for the sketches man, I like the style and will do something similar - although I'm thinking aysymmetrical. I'm posting pics of the mask and first sword so far tomorrow and will keep updating as I go along.
p.s. DO GRUTLE! He's awesome!
edit - forgot to mention, had an idea a couple days ago that would hint to fans of the malazan series who I was cosplaying. I was going to put a kiss on the mask in lipstick - from Lady Envy. What do you think.....