For Christmas I made my DH a Jedi Bath Robe. I found the pattern on instructables.com
although I did make a few adjustments.
http://www.instructables.com/id/Sewing_a_JEDI_or_Harry_Potter_Robe_or_Cloak/

I got 4 yards of fabric... well my DH is not a small man.. I should have gotten 5.  Because of this I had to make the hood in 3 parts. Each side & the front band (6" wide for 16" folded in half)  I used a 1/2" hem all around.
The fun part of the project was getting the measurements... like I said it was a Christmas gift...   I used one of hubby's dress shirts to get most of the measurements.  I used my younger brother's head for hood measurements.
The biggest problem was getting the "top of shoulder to floor" & "underarm to floor"  I enlisted the help of my father for that one. He was gonna kinna stand by hubby & "eyeball" where those spots fell on him so I could measure him instead.  But instead of that... Hubby ended up coming inside & hugging me... so I kinna snuggled up to him & measured it on me :P   apparently his underarm is right at my top shoulder height & the top of his shoulder is right under my chin.
Then I had to lock him out of the room to be able to sew it.  I had to use my poor brother again to hem the bottom.  It was pretty funny..  Hubby is 5'10", Brother is 6'2".  Hubby is built like a football player... brother is built like a basket ball player... it was SOOOOOO funny to see him in the robe. I had to squish the shoulders us so that the hem fell flat.
Something that I had found out a few weeks ago... my thigh is the same around as my hubbys upper arm!  Guess how I  measured the fit of the arm holes :P  yep.. wore the thing like pants.  :P
I also added loops for the belt (added along the hemline)
and after all this... he figured out what it was before he opened it...  *sigh*   oh well.  He LOVES the thing.  It's very warm.   I made it out of "No Pill Fleece"  which I got at 50% off from Joanns (WOOTTT!!!)
Now hubby wants me to make another one...  for the baby. I think I may just make a hooded towel..

  17 weeks down 23 weeks to go..