I made an apron for my chef roommate for christmas this year:http://www.styrofoamkitty.com/content/Holidays03/deathchef2.jpg
At my local cooking store, I found a white cotton apron for $4. I dyed it black with Rit Dye.
I used iron-on letters I had laying around the house for the wording.
I found a good skull & crossbones in a clip art gallery and blew it up and traced it with white felt (25c) and cut it out and stitched it on with embroidery thread (33c).
I bought these metal spike studs at the local craft store in the leather-working section (i guess punk rock has totally been homogonized, huh?) and I hammered them on. They were kind of expensive, at like $6, but I only used half of them.
But hey, my roommate liked it!http://www.styrofoamkitty.com/content/Holidays03/stevedeathchef.jpg
Sorry the pictures are so big, I'll resize them on Monday.