Halloween is the greatest time of year!!!  I love making costumes but there is one simple rule I follow.  Only found or recycled materials can be used unless it is absolutely necessary to buy something.  Oh yes, and the costume can't be lame.  It has to be EPIC!!!

This is not really an instructable.  It is more of what I did to create this costume and hopefully you can use some of the ideas from it.  I didn't take as many pictures as could have been so you might have a few questions.

This costume was made for a Halloween contest (unfortunately the contest was canceled at the last minute due to poor ticket sales).  The only way I could get to the contest was by city bus so I phoned the bus company and found out the dimensions of their doors.  This costume stands about 7 feet high, 3 feet wide at the shoulders, and is about 2.5 feet front to back.

Oh, and there are no pictures of me in the finished costume.  I couldn't get it in my door to take pictures in the mirror!

Here is the material list:

For the paper mache; (Did I mention the costume is made out of cardboard and paper mache?)
-construction paper
-tissue paper

Basic body;
-old pair of pants
-red plastic from a plastic file folder
-strips of rubber for feet
-pieces of wood
-cloth for padding
-duct tape

Camo, words, and symbols;
-red latex paint
-black spray paint
-white spray paint
-yellow craft paint
-white craft paint
-red craft paint
-green craft paint

-plastic flower pots
-plastic tubing
-electrical conduit
-light switches
-cordless drill
-sheet metal
-metal tubing
-mini flashlight

-bicycle flashers
-lights that clip on to a hat
-2 6v gel cells

Smoke generator;
-electrical conduit
-metal tubing

-large sewing needle
-heat gun (to speed up the drying process for the paper mache)

There are miscellaneous items like screws and stuff.  The back bottles are from a water cooler I found.

I'm not going to describe how I made the smoke bombs for the smoke generator nor the ignitors for them.  Also the gun on the left (left side of the picture) fired special confetti shells I created.  They sounded like a shotgun going off and spewed confetti everywhere! But I made sure that it was absolutely safe by doing extensive testing with the shells and gun before putting it anywhere near my body.  So I'm sorry but I can't tell you how I did that.  It is very dangerous if you don't do it right.

As for the price, I think this costume cost me about $50 in materials.  Most of the materials were found so they were free.

Step 1: Working with the cardboard

I didn't follow any specific pattern or wanted to duplicate something I saw somewhere.  It was more of a create as it was being built kind of thing.

From previous experience, hot glue or any kind of glue tore the cardboard if the cardboard was stressed.  Since I was using paper mache, that was going to be the glue.  But it wouldn't be strong enough to hold the cardboard together (learned that one from previous experience as well) so I sewed the cardboard together with string and a very large sewing needle.  I think it was a bookbinders needle I bought from the dollar store.  I also used a hardware store stapler (already had one) to help hold things together.  Had to bend the backs of the staples down once they went through the cardboard so there were no protruding edges.

Before the cardboard was sewn and stapled together, I used the paper mache mixture (a thick paste of flour, water, and salt) between the pieces of cardboard to glue them together.  Then after it was put together, another layer of the mixture was spread over the string and staples to help hold them in place.

Each piece was fit to my body during the construction.  To join the upper and lower legs, cloth was sewn onto the cardboard and then sewn onto an old pair of pants with the string..  This made the joints flexible.

One of the pictures shows the back.  Another picture has some black rubber things in it.  These are the feet.  They are made out of paper mache and cardboard too but the rubber let the feet flex as I walked.
I wanted to say something about how really awesome this is, but my jaw dropped to the floor when I saw that it was made out of cardboard, and I have yet to find it again...
Thanks! You made my day! The whole idea of the costume is to step outside of the box (so to speak) and use your imagination to create anything you want to! Hopefully you now have a whole lot of great ideas running around in your head and soon you'll amaze all of your friends!
This turned out fantastic!! Well done!
Thank you. Tried to make it as simple as possible! Hopefully you guys can use some of the ideas from it for MEGA EPIC costumes! Costumes don't have to be expensive because most of the materials a person needs can be found or bought really cheaply.

About This Instructable


32 favorites


More by keokg2: Yet Another Self Watering Container CalvinTag Halloween Costume Tricks
Tags: Mech Battle Suit
Add instructable to: