Well, it's been a while, but the fans have apparently not forgotten Zael's travesty of a costume. (How could they, when he's still wearing it?)
This is one fan's interpretation of how the hideous thing was created.
http://i75.photobucket.com/albums/i295/meian_no_miko/Arrancar_Antics___5_by_oneoftwo.jpg ...Noitora is so going to rape you, Zael dear.