my first kcon I went as rock lee. I took some leather boots, cut out the toes and the heels, then spray pained them blue. it was wonderful except that the front parts where it would cut rubbed against the sides of my feet, and they were raw. bye the 3rd day they actually bled right after I left the hotel room, so I didn't cosplay that day. probably the worst injury.
OR!!!!
when I was dying my rock lee jump suit in the giant pot on the stove, and a -bunch- of water spilled out. I caught the pot as it was falling, and since it was metal it shocked the crap out of me and I fell and hit my head on the kitchen table