Picture of Alien Xenomorph costume

For the past few years I have been making a couple of homemade costumes for my boys each Halloween. Last year I made a Masterchief following some of the advice from this site and it turned out pretty good. This year my youngest boys told me they want to go as Alien VS Predator. Well I knew that this was going to take a bit of time so I started in September. I decided to start with the Alien, arguably the more difficult costume, not finding too much advice for making a homemade Alien costume I had to get more creative. Did I mention that I am leaving one job and starting another so I only had a budget of about $25.00?

Step 1: Building the Head

Picture of Building the Head
august 2011 017.JPG
august 2011 018.JPG
august 2011 019.JPG
august 2011 020.JPG

The Alien head seemed like the most difficult part to me... How to get that elongated tubular shape? And how to get it to stay on the kids head?  Well, I started looking around the garage.  Digging through the clutter I came up with an old bicycle helmet.  being made of Styrofoam it was pretty easy to shape.  I started by cutting the sides down to the bare minimum so my Alien didn't have too bulbous of a head.  Now we needed some tubes.  The local dollar store came in very handy, I found several 3 quart plastic containers and a plastic pitcher that seemed very promising.  Total cost? $3.00  doing good.  I cut the containers up and hot glued them onto the helmet. By the way... I went through two bags of hot glue which are about 4 bucks apiece.  Then I cut the bottom off of the pitcher, cut that in half and I had my Alien Jaws.  A little marker to draw out the teeth, sharp scissors and boom.. we had Alien teeth. I used scrap pieces of the pitcher to make the rest of the Jaws.  The head needed a little rounding, fortunately I had several empty 2 liter bottles.  By the way, careful with hot glue around two liter bottles, they wrinkle and shrink if the glue is too hot.

Step 2: Continuing the head.

Picture of continuing the head.
august 2011 024.JPG
august 2011 025.JPG
The Alien jaw needed a little more depth, so I turned to dollar store fun noodles.  Wonderful, cheap, closed cell foam, they worked wonders.  I figured we needed some lips too so I broke out the coat hangers.  Just heat up a screwdriver and melt a little hole for the hanger to fit in.  A little more foam to fill out the neck and we are on our way.  it's starting to look pretty good!

Step 3: Finishing the Head.

Picture of Finishing the Head.
september 2011 002.JPG
september 2011 003.JPG
september 2011 004.JPG
september 2011 005.JPG

Alright.  We need some kind of neck. Off to the thrift store!   The local thrift store had a wonderful 2 dollar bag sale, so I stuffed a long black fake leather coat, black tights and a black long sleeve shirt into my bag. $2.00!  So far well within my budget.  When you cut up the vinyl fake leather it glues quite easily to the plastic.  So now I have a neck and lips.  time for some features.  The Blue tube is empty 3/8 electrical flex that I had floating around. for the other ribbed sections I used an old pool pump hose that I had cluttering up the garage. A small piece of rope, artfully cut piece of cardboard and two blue balloons for cheeks and I was set. Time for that black paint!  By the way, cheap black paint and vinyl don't mix.  The paint reacts with the vinyl and takes on this nasty sticky texture which is very difficult to get rid of.  So, before painting anything with vinyl on it, get some good plastic paint.  A couple more two liter bottles  to fill holes and we have a basic black alien head.

Step 4: Finishing touches, now the body.

Picture of Finishing touches, now the body.
september 2011 003.JPG
september 2011 004.JPG
september 2011 006.JPG
Looking pretty good.. but the teeth look kind of flat.  Time to head to the discount store for some..... glamor nails!   A pack of 100 nails was surprisingly cheap.  Cut those babies down, even more hot glue, some silver model paint and our Alien finally has some bite.  The inner mouth is a pair of cheap glow in the dark vampire fangs glued to a toilet paper tube... cut down the tube and paint the fangs silver too.  Have I mentioned hot glue?  Most of the texture and details are just carefully applied hot glue. A couple of Velcro tabs to hold the neck together and the head is done.

Step 5: The body

Picture of the body
september 2011 002.JPG
september 2011 005.JPG
september 2011 006.JPG

The body came pretty easy after the head.   Card board plates for the front and back.  More fun noodles for the back horns. I used coat hangers inside the noodles to get them to hold the right shape.  Cereal box cardboard for arm plates horn plates. Lots of hot glue for texture. I cut strips out of the fun noodles for the ribs, a strip of pool hose for the sternum and then covered that with a cut out piece of cardboard.   The ribcage needs Velcro tabs in order to make it  fit securely enough. Shoulder plates are mare out of more cardboard with fun noodle tops,  held on with Velcro strips.  Lots of pool tubing strips on the belly and neck for texture.  Gloves are fake leather with extra thumbs glued to the bottom. Made out of that vinyl coat I bought.  I used that fake leather on the legs also with more hot glue for detail. Oh yes... the tail.  that used to be a stuffed snake. cut cardboard vertebra out and hot glue those suckers on.  By the way.  in order to paint a brightly colored fabric snake black, you must use a LOT of paint.

Step 6: Finished!

Picture of Finished!
Alien thumbup.jpg

A couple of finishing touches.. nails on the gloves and shoes... even more hot glue and black paint. and we are done!  Now I need to get started on the Predator.   Hope this helps if somebody wants to make an Alien Xenomorph.. all you need is cardboard, plastic containers a lot of patience and.... Hot Glue!!!

Thats an amazing build!

seresataka (author) 1 year ago
Thank you so much. I have a big costume project cooking this year.. hopefully I'll have time to finish it before halloween
ness02071 year ago
I am sooo happy to find this! My boys are wanting to be alien vs predator this year & this gives me hope! This will be my first attempt at making a costume from scratch, I can only hope it turns out as good as this!
rkeefer2 years ago
i must just say this is pretty sweet, best dad ever :)
seresataka (author) 2 years ago
I don't know... probably could, but my kids have other costume ideas this year.
wmiros2 years ago
Awesome can you make a face hugger
Garrus2 years ago
Thanks for this guide! I've convinced my 6 year old sister to be net-head. I'm even making her a fake facehugger. If anyone's interested i could make an instructable for that, but its not as cool as your stuff really amazing.
avpg2 years ago
I've made 4 alien costumes now I am goanna try this way now thanks for the instructable keep making more maybe a face huger next??????
Cool. I like it. About how much time is needed to make it?
the coolest thing ever is an alien xenomorph so I'll give you two thumbs up.
Kiteman3 years ago
Oh, that is just outstanding!
yes I agree
jhd043 years ago
I was like, "Whoa, that's really cool." And then I saw the budget, and I was blown away.

Very talented, you are, sir. Very talented indeed.
jpnagle593 years ago
A very well build...you are to be commended. If you can, let us see the Predator build. and also get some shots on the Spooky night when the kids wear them...very good job. Jamie
brainsfried3 years ago
Terrific Instructable and great job on the costume!
Patjoe993 years ago
Wow you are the mot creative,most make-do, most talented costume creator ive ever seen when i saw the i think, wow thats gotta cost at least a hundred dollars then i see it was about 25 dollars
sutek3 years ago
Mate you win the most Awesome Dad in the world contest, that is fantastic and the work involved, amazing. You've got my vote
you are amazing :3
i have been looking for an easier way to build a xenomorph (alien) costume for a lonnnggg longggg time and now i have the answere XD
thank you so much for making this guide!
time to get started on my costume :P
Jerrib3 years ago
bravo.....you give me hope!!
that kid doesnt look very happy.....
seresataka (author)  lordofducttape5453 years ago
After the third or fourth time test fitting it that night...... he wasn't.
YES!!! LOTS and LOTS of HOT GLUE!!!!!
Excellent stuff. That is all.
orvis3 years ago
Really excellent costume, especially for the money. You have a talent for making mundane things and making them extraordinary.

I really do admire your thrift and industry! My perfectionism always seems to get the better of me, pulling me into obscene hours of crafting, usually at the expense of actually getting it done.

Well done.

A doing it on the cheap too! My kind of costume making 5* and kudos to you for such a great job, I have been inspired to bust out the cardboard and get gluing.

I really like the translucent look of the head in Step 1, it looks like a newly laid infant very cool!
Thank you everyone.
macgeek3 years ago
This is EXCELLENT!! - Really creative and wonderfully done!
You should enter this in The Halloween Contest!

Jonathan / Zoltar - winner 2009
seresataka (author)  macgeek3 years ago
I can't seem to find a Halloween contest for this year. Thanks!
mpatterson43 years ago
Awesome! How is the view from inside? Does the child look out through the mouth or from under the head? How well can he see?
seresataka (author)  mpatterson43 years ago
not too bad actually. I cut the eye holes in the vinyl right under the head, so he looks through the aliens neck. His vision upwards is blocked but he can see his feet quite well and about 6 feet in front of him. to see farther he has to tip his head back. Thanks!
Phil113 years ago
superb work, your son must be really happy with that!
dburrill3 years ago
Now that's a Halloween costume. Halloween is a time for scaring the be-Jesus out of the little kids. It's the only time of the year when it is permitted. I say that there should be a law, why not since there are laws against every thing else, that on Halloween there can be no cute little ghosts, cartoon characters, angels, or any such costumes.
sarawelder3 years ago
This was an excellent instructible... make me think that at 59 I might have a costume party just so I can wear this
time-killer3 years ago
VERY cool! well done.
festeezio3 years ago
Wow! Nice job!
luc.dof13 years ago
Very good, it's so fun. And Good Halloween
Lorddrake3 years ago
AMAZING!!! 5 stars for creativity and resourcefulness.
Cabe3 years ago
Great job!