Thanks for your nice comments, its always good to talk to other people who know how long things take to make!
@eclectic I didn't time it because it was not a commission but I think it took about 60 hours - for the measuring, pattern making, fittings, dyeing, sewing, painting, embellishing. I had to do various batches of dyeing because some was nylon and some polyester and I wanted various different colours and shades. Acid dyeing nylon is quite fast if its only small quantities of fabric. The thing that took longest was just working out where to put all the bits and sewing them together.
I've only made about 20 competition leotards (so not 100s) but I think that between 25 and 60 hours is a good estimate depending on how elaborate the costume is and whether you need to draft a pattern etc. I'm not including in that estimate the amount of time I spend making sample sections and strips.
@Twan - yes Jacquard paints are lovley, I like the dye-na-flow. I like the dyes from Kemtex as its a good price and they give great advice but Jacquard do have a lovley range. I find that the paint tends to rub off - which I suppose is to be expected with a dance or gym costume - how do you find them? I try to use acid dyes (on nylon lycra and mesh) when I can because the colour is deep and rich, but the dye can run when the fabric is washed so that can present issues with dyeback onto pale areas. I'd be interested to compare with what other people do.
@Marniesews - hand cramp - that made me laugh, I got it last week removing crystals and unpicking another costume. Remember getting it at school during exams!
Al