Introduction: Be a Ghostbuster for Halloween!

Picture of Be a Ghostbuster for Halloween!

I thought this would be a great idea for Halloween (I love Halloween!) so in my usual over the top fashion I went, well -- over the top. A buddy of mine wanted to do it as well. We tried to get his roommate into it too so we could have a third Ghostbuster but he didn't think we'd be able to do it......... :D

I made two complete packs, suits, belts and goggles in just over two weeks working mostly nights and weekends. I also made a ghost trap and pedal- it clips onto the belt just like in the movie. The guns come off the packs and the packs light up, as does the trap. I made two lighting circuits for each pack using a simple homemade 555 timer circuit, a few LEDs and 9v batteries. The trap weighs around six or seven pounds and the packs weigh about twenty- five pounds.

The packs and trap are pretty movie accurate- they were made from plans that were drawn up from one of the original movie "hero" packs on display at Planet Hollywood. The A.L.I.C.E. pack frames are the same as the movie and were purchased from an Army surplus store. Most of the small parts on the pack are movie accurate and were located at a local electronics surplus store. Even our coveralls were from the original movie supplier. The "no ghost" patches were bought online.

I made the goggles from hardboard, Bondo and thin plywood. I turned the aluminum and glass lenses on a lathe. All the labels on the packs and goggles are accurate and were printed on my computer.

Like I said- over the top. But come Halloween it is oh sooo worth it. People go absolutely flippin' nuts when they see the whole getup. They absolutely cannot believe they were homemade.

This is a BIG project so I'll basically outline what I did to make it go a lot faster. Follow on...

Step 1: Gather Materials and Resources

First you need to download all the plans, labels, templates, etc. Give a huge thank you to all the guys that have worked on this stuff over the years! Everything is here:

The main ingredients I used to build my pack are blue insulation foam (available at Home Depot), MDF wood, 1/8" thick pressboard and lots of epoxy. The ALICE pack frames can be purchased from Army surplus stores. Also locate a good electronics surplus store for a lot of the small parts.

Step 2: First the Suit

Picture of First the Suit

The suit is a standard beige flight suit. You'll also want black rubber gloves, black boots and a military style belt. The arm pads are actually knee pads from a sporting goods store- mine aren't the "correct" ones but they were cheap.The "no ghost" patches and name patches can be purchased here:

The pouch on the belt is a modified tape measure holder with little lamps glued onto an old circuit board. The actual movie ones used Nixie tubes... Use another old circuit and attach a coiled phone cord to it- this then hooks onto the back of the belt. The clear hose (it's a mystery)goes from the front of the suit (use a hose barb through the fabric) and attaches to the back of the belt. There is also a keychain clip that goes on the front of the belt- they used it to hold the proton wand in the movie. The name patch I used was made with velcro and fabric paint.

Step 3: Start Making the Pack!

Picture of Start Making the Pack!

This is that hard part. Study all the plans over and over. The motherboard is made from 1/8" thick board and is bolted to the ALICE pack frame. The spacer is made from blue foam as are the gearboxes, Ion arm and bumper- this speeds things up dramatically and really cuts down the weight of the pack. The cyclotron is made from MDF rings and 1/8" thick board. I ended up using flashlight refelectors with red LED's in them for the cylotron lights. The lenses were made from translucent plastic folders.

The powercell is made from 1/8" thick board and is held in place with screws, making it easy to remove for battery access. I used another plastic folder (blue) to make the powecell lense. I made the gun hook from a piece of 1/8" thick aluminum sheet but a lot of people use a Dixie cup dispenser hook. I machined my own knobs and Ion knob but many people use stacked washers for the Ion knob. The N-filter was made from a can.

The trick to working with foam is to finish it properly or paint will melt it. Once your foam is cut to shape sand it lightly and smooth all the surfaces with a lightweight spackling paste. Then cover it with Minwax Polycrylic sealer. This will allow you to paint it with good old black spray paint. It will also make the foam a little tougher.

Step 4: The Proton Wand

Picture of The Proton Wand

This is made mostly from 1/8" thick board. The grips were carved from blue foam and the handles are PVC pipe. The clip that is mounted on the underside of the proton wand body hooks onto the proton pack so it can be removed- just like in the movie. I made the side plate removeable and stuck a lamp in there- it's turned on by one of the toggle switches on the wand body.

I also added lights to the powercell and cyclotron in the proton pack. They are each based on a simple chaser circuit and use LED's and are powered by a 9v battery. They are actually quite bright in person.

Step 5: The Trap and Pedal

Picture of The Trap and Pedal

The trap body is made from 1/8" wood and MDF and the handle is a dowel. The sideplates are thin aluminum sheet and are epoxied on. The pedal is made from some aluminum door kickplate (attached to the base with a hinge), MDF for the base and has a 2 1/2" flexible ducting hose hot glued underneath it to act as the bellows. The relay and other electronic parts/knobs came from an electronics surplus store and are attached to some plastic boxes that are screwed to the pedal.

The trap lights up ( I used the same LED chaser circuit as the lights for the proton pack) and the trap doors open. The trap has a catch plate on the underside (same as the proton wand) and a matching plate on the belt holster so it can hook onto my belt. The pedal then hangs over the trap by hooking the gray cable on top of the pedal over the trap handle.

Step 6: Goggles

Picture of Goggles

These were made by making the basic frame shape from 1/8' thick board and then making a curved flange on the back by bending some super thin 1/64" plywood (this can be found in some hobby shops.) This was then smoothed with bondo. The lenses were made from old microscope lenses I bought for one dollar each. I made PVC rings to go around them and added the small knobs. I then attached some foam weatherstripping to the back of the frames.

This is a VERY abbreviated tutorial (a step by step could fill a book) but is shows that with a little creativity it's really not that hard to make a great Ghostbuster costume in record time.


SalvadorP (author)2015-05-23

Thanks a lot for making this article, I'm planning on doing a pack for my son, and i want to use that foam they sell for insulation, im guessing its the same one u used, im in canada and mine is pink, was wondering what glue did u use to glue the foam together?


Honus (author)SalvadorP2015-05-23

Yep- that's the same foam I used. The best glue I've found to glue foam is epoxy resin- pretty much any epoxy glue will work.

codysmeme (author)2015-02-05

Hi, I hope you get this message since the previous comments are a bit dated. My grandson will turn eleven in March and he is a Ghostbuster fanatic. His Birthday party is a Ghostbuster theme party. He has wanted the ghost trap for years now. Mattel is not planning on having any made and Ebay is way out of my price range. You obviously know what you are doing, would you consider selling yours? He would be content with just the box as long as the doors open. Would this be something that you might consider? Thank you!

mcase7 (author)codysmeme2015-03-06 has a trap kit made in resin that's super easy to put together

codysmeme (author)2015-02-05

Hi, I hope you get this message since the previous comments are a bit dated. My grandson will turn eleven in March and he is a Ghostbuster fanatic. His Birthday party is a Ghostbuster theme party. He has wanted the ghost trap for years now. Mattel is not planning on having any made and Ebay is way out of my price range. You obviously know what you are doing, would you consider selling yours? He would be content with just the box as long as the doors open. Would this be something that you might consider? Thank you!

Honus (author)codysmeme2015-02-05

Hi there! Unfortunately I don't have my ghost trap any more as I gave it to a friend several years ago. Sorry!

sabrinab1 (author)2014-11-14

Do you build working Ghostbuster Replica Traps. My 8 year old son is wanting one for Christmas and I cant find one. If you know where I could get one please let me know. Thanks, Sabrina

email is

Honus (author)sabrinab12014-11-14

Sorry but I don't build traps or sell them. I'll definitely keep my eyes open for one for sale and I'll be sure to let you know if I come across one!

chaise.villers (author)2014-08-11

Hello! im working on a proton pack myself and i just have a question.

Where did you get the hose from as well as the elbow pads?

Honus (author)chaise.villers2014-08-12

I got the hose from a local electronics surplus shop. I honestly don't remember where I got the pads- it was so long ago. I think I got them at a sporting goods store.

jpolfer (author)2013-10-02

I'm curious how you did the Cyclotron lights. My buddy built a proton pack for Halloween 2 years ago, and I helped him do his Cyclotron chaser lights.

We used the biggest red LEDs we could find at Radioshack, and backed them with tinfoil. Then I wrote some simple BASIC Stamp code to flash the LEDs, put the BASIC stamp on a small PCB with drive wires on it. and then put a power switch on the outside rim of the pack. We powered it with a 9V.

Instead of soldering, we used electrical tape to secure all leads.

Honus (author)jpolfer2013-10-02

I used a simple 555 timer circuit like this one for the cyclotron and power cell lights-

Some day I'd like to revisit this costume and make it really nice with a really detailed instructable- it's still probably my favorite costume.

jpolfer (author)Honus2013-10-02

I see... I would highly recommend *not* calling that 'a simple 555 timer circuit'. Because its really a 'simple 555 timer circuit feeding a CMOS counter IC' That's pretty different.

When my buddy was building his GB backpack, he kept telling me all you needed was a 555, and I for the life of me couldn't figure out how you would build a light chaser with just a 555. Apparently that was Ghostbuster-pack-builder-shorthand for that circuit.

Aust1983 (author)2013-01-06

My bro's son will have a themed birthday party and I think I have found my costume :)
Thanks Honus, this looks impressive and brings back good memories of my childhood. Thanks for sharing, I have faved this and shared on my fb page. Cheers.

Honus (author)Aust19832013-01-07

Thanks- glad you like it! I still think being a Ghostbuster is one of the best costumes ever. :)

BigChasMiller (author)2012-11-09

Have you had anyone ask you about modifications for a child, say 4 years old.

Honus (author)BigChasMiller2012-11-09

I've seen a few kids Ghostbuster costumes where people just scaled down the pack plans and went from there. The suit may be hard to find in kids sizes though.

fsalazar3 (author)2012-10-13

i've wanted to do my own suit and props for years now,i'm not that electrical savvy so i'll probably do cardboard versions of the pack and props, but maybe i'll take a crack at doing a more sturdy pack. you've inspired me to get back to my dream of being a ghostbuster for halloween or maybe home movies :)

Naters (author)2012-09-22

Awesome costume! congratulations it looks amazing

Honus (author)Naters2012-09-23


Sharaz Destler (author)2011-07-04

Nice. There are so many proton packs on the web, but I guess it's just a really popular prop. I've been drawing up plans for the Ghost Dematerializer mk I from the 1975 TV show "The Ghost Busters" with Larry Storch and Forrest Tucker. It's best known for the 1986 animated sequel--both were made by Filmation.

I have...quite a few measurements, actually, and have done a fair amount of research. I'll share 'em with you soon, Honus.

Honus (author)Sharaz Destler2011-07-05

Proton packs are popular- I've seen everything from cardboard versions to super accurate molded fiberglass packs. I've never seen one from the 1975 show- that would be neat to see. I think I've only seen one or two of the Ghostbusters Extreme packs.

greatscottbttfride (author)2010-11-06

nice video how do you make the led light spin like that ?

Honus (author)greatscottbttfride2010-11-06

Just use a chaser LED circuit. Most of them are simple 555 timer based circuits. There's sample circuits all over the web.

greatscottbttfride (author)2010-11-06

hey are you on ?

Honus (author)greatscottbttfride2010-11-06

Yep- I just haven't been there in a very long time.

greatscottbttfride (author)2010-11-06

cool stuff their

milemt (author)2010-10-29

The suit is a desert version of the flight suit usually can be found for less than 20 bucks at an army surplus.

gazillion114 (author)2010-09-11

what buisness?

dramaplay (author)2010-08-31

Great Suit! I have to make 30 of them for a special needs program for next summer..... Can you tell me how tall the name patch is? Thanks.

Honus (author)dramaplay2010-09-01

The name patch should measure about 5" long x 1.75" tall.

dramaplay (author)Honus2010-09-01

Thanks. -dramaplay

Cerberus894 (author)2010-06-19

Hey, thanks for the info. Now I have another question. How did you attach the hose barb to the suit?

Cerberus894 (author)2010-06-13

Hey man, nice work on the suit, and the pack. I have many questions for you, but the first is where did you get the velcro for the name patch? I haven't been able to find a suitable replacement for the actual name patch other than buying a bunch of patches with my name on it.

Honus (author)Cerberus8942010-06-13

I bought some wide velcro from a hardware store and put the name on using fabric paint.

Cerberus894 (author)2010-06-13

Did you make your pack with working lights, and things like that?

Honus (author)Cerberus8942010-06-13

Yep- it does have working light, but no sound effects.

Inara (author)2010-03-02

This is so wonderful, I actually teared up a little when I first saw it.

MarcusAvery (author)2009-11-04

This is AWESOME! I know it's too late this year, but next year, I am SOOO going as this guy! GREAT INSTRUCT ABLE!

cordless drill (author)2009-10-29

That's funny!! LOL but I have to say it's a pretty cool idea.

kitkat09 (author)2009-10-12

Thought this info would be helpful....we found some great (and affordable) coveralls at

They have a relaxed and regular fit.

michael lively (author)2009-02-26

so I'm guessing that you would get the beige flight suit form and army surplus store right... or is there a website for it?

kitkat09 (author)michael lively2009-10-12

My husband made this costume this last year for Halloween. He got his tan coveralls from this store...

He also bought goggles and boots there too to complete his outfit..

The total for his order was under $30! Cheap!

For his "backpack" he painted a box black with a bunch of buttons on it and attached an old shop vac hose...

Honus (author)michael lively2009-02-26

I have found them online but that was several years ago- I'm sure they're still available.

michael lively (author)Honus2009-03-10

so like it is something that you have to stumble upon.

Gakki (author)michael lively2009-09-06

Do a search for "surplus Flight suit" you'll find them quick. Nomex is the most acurate and also the most expensive.

bravotreble (author)2009-10-05

can't get over how awesome all your stuff looks. where did you get the dimensions (height, width and length) to build the trap? or maybe i could make this easier and just ask you the dimensions of the trap you made

Honus (author)bravotreble2009-10-05

Unfortunately I no longer have my trap so there's no way for me to get dimensions from it. There are trap plans at and I also posted a link to a set of trap plans in another recent comment.

Nykus79 (author)2009-10-04

wow the trap! I want it!... can you make me one? :)

Honus (author)Nykus792009-10-04

Sorry I can't- but you might have a look here:

About This Instructable




Bio: I'm a former bicycle industry designer turned professional jeweler. I like working with my hands and am happiest when I'm in the shop ... More »
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