This year he chose the Power Ranger Mystic Phoenix Titan... yes, of all the characters out there, he chose this... he chose an obscure 6+ year old Disney mixup of the Mighty Morphin franchise. That's what happens when you leave it up to a 7yr old.
The project took about 25-35 hrs, I lost track of the total time. I chose to tackle the project with more of a "hand made" look, rather than a full reproduction. For a one-off halloween costume I try to balance time and an overall impression. If this was yet-another-ironman costume that could be worn for several years over, maybe I would have taken a different approach, however I also wanted my son to participate in the process and solve as my design issues as possible with these limited resources.
Hot Wire Cutter
3M 77 and 90 Spray Adhesive
*Glossy Red Duct Tape
*Extra Wide Black Gaffing Tape
*Thin Black Gaffing Tape
*Black Masking Tape
*Clear Packing Tape
*Paint Masking Tape
*Aluminium Foil Tape
Kitchen Aluminium Foil Wrap
8'x4' Reclaimed Sheet of Insulating Construction Foam-core (can be purchased from Home Depot)
Recycled desktop computer box
Recycled cpu box
Recycled Kid warmup sweats and hoodie
Pair of Gloves
Found Floral Hemisphere (can be purchased from Ben Franklins)
Step 1: Shoulder Pads and Basic Fittings
As it turns out, a basic computer shipping box with two sides of styrofoam padding turned out to be the exact size for not only the shoulder frame, but the wrist guards (see step 6). The shipping foam was a little wide, but considering the need for mobility and the minimal emphasis on accuracy, I decided to it would do.
To frame the shoulders, I used pretty much the only image of the Titan I could find and sketched out the basic pattern on 11x17 paper. Newspaper would do just fine, just something as a template. After cutting the template up, I put it against the Foam Core and carved out the shape with the hot-wire cutter.
I attached the walls of the shoulders to the frame with 77, careful not to spray it directly on the Styrofoam-- it melts it to shreds!
I cut-and-creased some cardboard around the edges, securing it with 77 to the foam and T-pins to hold.
Cut a hole for the head- I used a cerated carving knife and smoothed with the hot-wire cutter.
The Face Mask was quickly constructed from the leftover motherboard packing foam. Hot-wire cut to fit a small head.
Finish it off with a fitting. It's good for morale for both kiddo and dad!