If I had a current "best" it would be my Mordred Cosplay hands-down. It was one of two costumes I made for one shoot once again. (Both casual and Phase 4 Mordred) but the shots and my poses turned out rather well and fitting for the character!
Phase 04 Mordred took around 2 days to create patterns for, and then finally sew and adjust. I had huge issues with that hip "skirt" that floated quite a bit. There's also the beautiful gold accents that I was anal about. (Had to scrounge around for the right shade)
Casual Mordred took a day and coincided with my Tatsumaki costume and shoot as well, as I seem to have gotten the habit of doing more than one costume at a time.
So..Moral of the story?
There are visual improvements, even if you feel like you've hit a dead end. I personally thought, that Fremy was the best I could do, EVER. So here's to proving ourselves wrong in the best possible way!