Thursday, November 1, 2012

Lego Man Costume


There couldn't be a more perfect Halloween costume this year for our Lego-lovin' Gus.

Eric really took his cardboard construction skills up a notch. He made this whole thing out of blue cardboard, red foam board, hot glue and Smoothfoam™. The legs were a challenge. It wasn't until after we saw Gus shuffling at the school costume parade, that we decided we needed to cut the backs of the legs open so that he could actually WALK and go up stairs. Poor kid. He was a Halloween trooper once again. I promised him last night, one of these years, we'll make him a costume he can actually walk, see and move in. He didn't seem to care. He loved it just the way it was.

Everything was handmade, except for the head. We bought one of those Lego containers that you can use to sort & store Lego bricks, cut out the insides and drilled larger eye holes. It fit perfectly. We used a red sweatshirt for the arms, and stuffed them with some of Eric's old, 4-inch vacuum tubing from the woodshop.

Now that Halloween is over, and we have no storage space left for a costume this size, I think it's going to go on permanent display in Gus' room.






I started to take photos of how Eric made this and then I gave up. Oh my lord, it was very meticulous and involved lots of calculations, cutting, scoring, tabbing and gluing. I don't know how that man's mind works, but I'm just glad it does. There's no way I could have constructed something like this so perfectly. Anyway, here are a few photos of the process and the finished pieces. Knock yourself out if you want to attempt one yourself!












28 comments:

Jennie henderson said...

I nominated you for a Liebster Award--check out the details here:

http://jennie-henderson.blogspot.com/2012/11/get-to-know-me-liebster-award.html

Justin said...

your costumes are awesome! our owl costumes turned out great thanks to your ideas. -justin

Project Denneler said...

Thanks Justin. Happy to hear that my crazy ideas can inspire others. ;)

Brian (tedbkd1@yahoo.com) said...

great job! how did u get the right paint color? did u paint match? how did u apply the paint: brush, roller, spray? also, what was the process on the Lego logo? one last thing: from what did u make the hands? thank u!!!

Project Denneler said...

Hello Brian - we didn't paint this costume. We used red and blue presentation boards that we bought at Hobby Lobby (those 3-panel, folding kind). The Lego logo is just an image that I found via Google Images. I printed it out on my large-format printer at work, cut it out and spray-mounted it to the front. The hands are cut out of discs of styrofoam. We glued two, 8-inch circles together and then cut out the centers into the C-shape, and spray painted them yellow. Then we hot glued them to yellow gloves.

Anonymous said...

Hello ur sons costume is absolutely awsome ....... so how many presentation boards did you actually use for this whole project

Project Denneler said...

I think we used one red and two blue. (They were the 3-panel folding kind you can buy at Hobby Lobby.)

Hannah said...

This costume is AMAZING!

I've got the storage head, just need to cut out its innards. Can you tell me what sort of blade/cutter/tool you used to cut the storage head with please?


Project Denneler said...

Thanks Hannah - we used a jigsaw to cut the opening in the plastic storage head. You have to go slow so that it doesn't crack. And the edges were kind of sharp when we finished so my husband used a small handheld sander to soften them. Good luck!

Project Denneler said...

Forgot to mention that he cut the eye holes using a 2-inch forstner drill bit. :-)

Shana said...

How did you construct the legs with the rounded part--my son wants to be Emmett from Lego Movie this Halloween

Project Denneler said...

If you look at the photos, you can see that he cut two, rounded sides for each leg, then hot glued another piece of cardboard to the front, forming the roundover.

leslie said...

This is amazing! any chance you would sell this???

Project Denneler said...

Thanks so much. Sorry, it's not for sale. My son has it proudly displayed in his bedroom. He loves it.

Anonymous said...

Would you sell just the hands?

Project Denneler said...

Sorry, this costume is not for sale.

Anonymous said...

What did you use to hold up the pants?

Project Denneler said...

We glued elastic straps to cardboard pants. Similar to suspenders, but extra-wide so they wouldn't slip off his shoulders. I think we bought 2-3 yards of it at the fabric store.

Donna Ahmed said...

This is awesome! I'm trying to build it for my son this Haloween. Can you tell me how far below the hip does the top go till & how far above for the pants?

Project Denneler said...

The top and bottom overlap each other by about 6-8 inches. (If that's what you are asking?)

Anonymous said...

Can you tell me how wide the leg piece is and how deep from front to back? Trying to make two for my grandsons.

Project Denneler said...

The legs are 26 inches tall, 17 inches wide, and 12 inches deep (at the roundover part.) Our costume was sized to fit a 10-year-old boy who was 5'3" at the time. Yours may need to be smaller or larger depending on the child.

Anonymous said...

Was it easy for your son to walk in it??? How much space is available for walking? This is amazing! !

Project Denneler said...

Unfortunately, no. This costume wasn't very easy to walk in and stairs were difficult to maneuver. We ended up cutting the back sides of the legs so that they would open and give him more room to stride, and that helped some.

shona bartlett said...

How did you make the hands? This is an awesome idea!!

Project Denneler said...

We glued together some 6-inch styrofoam rings, cut them into a C-shape, and painted them yellow. Then we glued them to some yellow knit gloves.

Bill Newton said...

Building one of these but sure how to angle the top part of the box so that it's not just a square box. Have some moving boxes form Lowe's but not sure how to give them more a slant as it goes up toward the head (hope that makes sense). Any advice?

Project Denneler said...

We did not start with a box. Ours was built using individual, shaped sides, that we taped and hot glued together.

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