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1 Head Front Unpainted.jpg
2 Grill.jpg
3 Chest Unpainted.jpg
7 Chest head & Torso complete.jpg
8 Feet Unpainted.jpg
9 Legs Unpainted.jpg
12 New Head Painted Back.jpg
14 Complete Front 2.jpg
15 Complete Side view 2.jpg
When first beginning my search for the most AWESOME Halloween costume ever created, I first wanted to pick something I've always loved... this lead to my childhood amore for Transformers which eventually became my Magnus Opus or Optimus Prime to be exact. Once I had the idea I shared it with my family and thus began the endless nights, thousands of Glue gun burns and my invasion occupation of my living room. I unshackled the little geek in me and let him run buck wild 'til his heart's delight.



All together I spent about $40 - $50 bucks, finding most materials from what I had in my garage or around the home.

Things you'll need:
- Hot Glue Gun (and sticks - the bigger the bag the better)
- Duct Tape (Red, Gray)
- Masking Tap (Mainly for paint)
- Small Ruler and Big Ruler
- Exacto Blade
- Scissors
- Spray Paints (Primer, Red, Blue, white and Mettalic)
- $.99 cents store Mini Flashlights (4 of them)
- Hard HAt (about $6.00 at any Hardware Store)
- Velcro (Found at Major stores like Target, Kmart etc.)
- Lots and lots of cardboard, or foam board. Most companies throw out scrap or just go to your local markets and ask them to save you some before tossing.
- 2 tin cans (emptied of course)
- 2 plastic report sheet covers (for the windshields)
- I used old Hockey Gloves but any cheap canvas ones will work.
- Packaging tubes or PVC piping

Over the last month I've found myself staring at piles of trash while driving, hoping to find something I can use for my costume. Always try to be frugal and inventive.

 
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Step 1: Creating the head

Let start with the head.

First select an old bicycle, snowboarding, or hardhat helmet that you never plan on using again.

From the Cardboard or foamboard
- Cut 2 ear flaps (Triangle shape)
- Cut 1 center unit piece (Retangle Shape)
- Cut 2 side discs where you plan on attaching the 2 antennae. (circle discs) Antennae.

Like most of this project it will be a series of trial and error to make things fit, the ear flaps are no exception. Once you have your desired shapes cut out, you'll need to cut circles on the inside to affix to the helmet with hot glue. Adjust fast because the glue dries quick.

The Center unit will present the biggest challenge as the concave center will need to be cut out with your best estimate then refitted for additional cuts. Remember don't over guess because you can always take off more, but you can't regrow once cut. Take your time on this fitting, it will pay off in the end.

Finally as for the side discs, just cut out 4 identical round discs, then for interior spacing take small scraps of cardboard and stack them like pancakes. Identical in number so both discs are even. Sandwich the small scraps with 2 discs and glue in place. Wrap then glue with out rim with a thin strip that covers the sandwich space. While drying cut out 2 long strips which will be the antannae (equal length) then measure out there width on the strip part of the disc. Cut slats on the discs just big enough to fit the antannae then put some glue on the tips and insert in the hold. Attach to the outer flaps and you've got an Optimus helmet.

Prepare for Painting by taping open areas of fabric with masking tape and any plastic bags around the home. Primer first, then paint over with the blue color of your liking.



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tacosmith says: Nov 10, 2009. 9:29 PM

My three year old wanted to be Optimus prime for halloween so I had to scale the costume down quite a bit. Thanks for the good design Idea!! He loved it and the family was impressed with what you can do with some cardboard and a bunch of hot glue:)

Zavprime.bmpPicture 091.jpg
jtigermask13 in reply to tacosmithNov 11, 2009. 6:24 AM
Tacosmith, great job, especially since it had to be scaled down tremendously...really awesome. 
thebeatjackson says: Aug 7, 2010. 11:45 PM
Thanks for the great instructable!
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Jollytime71 says: Dec 10, 2012. 6:18 PM
Ahh, so after a month of building, I was able to make this. I can't tell you how many pictures I took with people. It's SO awesome and fun to walk around in. With the added height of the feet and helmet, I stood just under 7' tall. And I took my little cousin trick 'r treating in it.
primecostume.jpg
kfh99m in reply to Jollytime71May 7, 2013. 4:57 PM
I like the suit. How did you make the gun?
DoorstopLex says: Nov 3, 2012. 4:19 AM
Just wanted to thank you for this fantastic Instructable. I took on your design and with but a few added touches of my own won first price at a Halloween party. People loved it and I have you to thank.
Unfortunately it wasn't finished, still needed a few touches here and there, but still went down a great hit.

Thanks again!
Doorstop
ybravo2 says: Nov 2, 2012. 9:18 PM
Thank you for taking the time to share all of your hard work with the rest of us. My 9 year old loved his costume so much! Thanks again :)
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Eireannach says: Nov 2, 2012. 4:59 AM
Awesome instructions! Took me every weekend for 2 months but I finally finished. Here is my Optimus!
optimus.jpg
Miketimus Prime says: Mar 27, 2012. 8:53 PM
HEY!!!!! IM DONE. well almost! YOU ARE AWESOME!!! hey yesterday I went outside with optimus and a man walks up to me saying that he wants to endorse the product!! If you want ill give you his number!!
Miketimus Prime says: Feb 8, 2012. 8:26 PM
This is my Optimus prime costume so far!!
transformers optimus prime costume.jpg
Doctronic says: Jun 22, 2011. 7:04 AM
Greeting Dannyeurena,

I took on the challange of doing my own Prime using our Prime as a blue print. I wore it last weekend for our pop culture expo, Supanova in Sydney, Australia. I could only wear it for a short time but when I did have it on, I could not move without everyone stopping me for a pic.

Took me over 2 1/2 months to make and had to cram in the time in the end to get it done. Still needs a bit of work done but the result was epic!!

Thanks for the blue prints. Without them I don't think I would of got this done. The pic's are a shorten pic history. Enjoy.
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Miketimus Prime in reply to DoctronicFeb 8, 2012. 5:46 PM
That's awesome, this helped me a little. what did you put in the leg to keep it on you shin? foam board?
frisbeechamp1983 in reply to DoctronicNov 10, 2011. 3:04 AM
NO, really get this off here, and post a photo 'ible!
frisbeechamp1983 in reply to DoctronicAug 31, 2011. 6:07 PM
post your own instructable rather than clogging this up.
ARJOON in reply to frisbeechamp1983Sep 4, 2011. 8:41 PM
exactly
tyler9050 in reply to DoctronicJul 19, 2011. 6:02 AM
i bet the guy in the assassins creed costume felt like a loser standing next to OPTIMUS PRIME!!!!!!!!!!
Miketimus Prime says: Feb 7, 2012. 7:37 PM
Hey I have been trying to make a Tranformers suit ever sense I was a very little boy! Thanks to you I can FINALLY fulfill my childhood dream. question how did you keep the legs (shins & thighs) to stay on? I am having a little trouble
Fireflyjunction says: Jan 26, 2012. 8:59 PM
Thank you so much for posting this! I made my own Optimus costume based on yours, with a few adjustments for being a girl and having a different... torso shape. My work has a four night Halloween party type thing for little kids and I ended up wearing it four hours each night, mobbed by kids and several adults the entire time.
Just a warning for other Primes-to-be out there: I did have a problem with several of the kids thinking I was a Real Steel robot and trying to get me to fight by hitting or kicking me. The parents usually told them to stop but after a while I had to find a buddy to try and stop them before they got close enough to hit. (For most of them you can tell which ones are going to hit you but they're really smart about coming in from your blind sides.) After spending hours and hours working on this costume it was extremely frustrating having it get banged and torn up. Be sure and bring along repair supplies if there's going to be kids around.
Team3313 says: Jan 24, 2012. 3:26 PM
I'm a guy from a robotics team and we're making this as our mascot. Helmet was easy but we're havin' trouble with the body.

Tips would be nice

Dimensions

Anything that you could give us so that we can have an easier time building it. Thanks man, your great.
lexkeepsitsimple says: Jan 20, 2012. 6:09 AM
What if you used real mirrors on the chest instead of painting the mirror effect? I never actually watched transformers when I was a little girl, but this looks awesome... but I am assuming that those squares on the chest are mirrors or something?
Team3313mechatronics says: Jan 18, 2012. 1:55 PM
Upon looking at your design I was wondering if you had demensions to follow at all?
psmarie says: Oct 31, 2011. 8:42 PM
Thank you soooo much for making this instructable! You totally made my halloween. We had sooo many people compliment us on it.  I made this costume for my 4 year old who LOVES Transformers right now. I spent a month (off and on) working on it (probably could've finished it in a week but it was a busy month), anyway, last night (10/30) he says
"ummmm, mommy, I think I want to be a Decepticon instead..." Honestly! The little monster. LOL.
Once he put it on though, he was so psyched to be Optimus. I think he was just yanking my chain.
Here's a pic of our finished product at the end of our night.
I had to make some adjustments to accomodate a child, like making it lighter... waaayyyy lighter.

For the shoes I only made the front halves and had them hinge directly onto the leg, so the shoe and leg were one big piece.

The leg pieces I cut at an angle at the bottom to accomodate a natural stepping motion. Worn with light up shoes it actually added to the costume.

I reinforced the folds on the inside with a finger swipe of caulk and it made the costume super sturdy on the folds.

My windows were cut from an old calendar.

I left out the sides of the torso because it added to much bulk to such a small frame. This really made it easy to slip on and off and because of the arm pieces you can't even tell the sides are missing.

The shoulders are attached with tiny hinges so they move up whenever my son lifts his arms outward.

### One thing I would do differently and something I would recommend for anyone making a costume like this for a small child is to make a template of the entire costume out of a very lightweight cardboard like a cereal box.

Before you glue any of it together, trace and cut out the same pattern out of Foamies (pictured below)
You can find Foamies by the roll (36" by 60") at craft stores like JoAnn Fabrics, Michaels, and Hobby Lobby for about $5 when it's on sale or you use a coupon. Just buy the colors you need for your costume, in this case, red, blue, and white.

With your glue gun, hot glue the foamies pattern ONTO your cereal box template (be sure to score your craft foam the way you would with your cardboard).

Construct the entire costume in the same manner (glue foamies to card then assemble).

Once it's done spray entire costume with a clear glossy spray. 

This will drastically take the weight of the costume down and it will add comfort and squirming room for kids that don't hold still.
I used the above technique on a different project so I know it works, I just wish I could've used it for this costume since cutting cereal boxes is so much easier than cutting stubborn cardboard LOL.

Oh, by the way, the lights on the costume are reading lights from the Dollar Tree. The helmet was started from a camo/soldier helmet also from the dollar tree.

Thanks again for this crazy awesome instructable.
:)
keith.jpgFoamies Roll.jpg
jon.melton says: Oct 28, 2011. 9:50 PM
Thanks for the instructions. Here's what we did, Optimus and Megatron. I may post instructions on Megatron later.
IMG_0524.JPGMEL_0341.JPGMEL_0330.JPG
chuckmccue says: Oct 26, 2011. 8:53 PM
I used a lot of the instructions on this page. It came out great! Thanks!!
deathnotx101 says: Sep 14, 2011. 1:51 PM
Only one thing need be said now........AUTOBOTS ASSEMBLE!!!! This was an awesome DIY, hope to get it up and running soon.

Quick P.S. in Chemistry when we were looking at telephone poles, and discussing the functions of all the equipment, when Mr.Censored said,"Do any of you know what a transformer is?"

Before I could register what I was doing I raised my hand and said,"Robots in disguise."

Also, when it was Halloween, my school allows costumes, I saw someone dressed up as Bumblebee, and when she sat down for lunch, TRANSFORMED INTO A CAR!
TubaJ446 in reply to deathnotx101Oct 23, 2011. 8:54 PM
I could imagine doing that, all the same I CAN'T STOP LAUGHING!!! And a TRANSFORMING BB costume?! Pure AWESOMENESS!!!
The nerdling in reply to deathnotx101Oct 13, 2011. 11:56 PM
"Before I could register what I was doing I raised my hand and said,"Robots in disguise."

lol, everyone would have laughed
days at school will be boring if noting like that happened:)
schtipp says: Oct 14, 2011. 2:14 PM
This is the end all, be all "how to" on optimus. Thanks for the great instructable. My four year old loves Optimus so I am making this for him. It is almost done. Just a few more finishing touches to go. Thank you so much for the great inspiration and instruction.
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ked1997 says: Aug 28, 2010. 6:48 AM
Does it transform?
loney1 in reply to ked1997Oct 9, 2011. 9:34 AM
No it doesn't unfortunately
loney1 says: Oct 9, 2011. 9:30 AM
I hope mine will be half as good Yours and everyone else's
timothycoblentz says: Sep 30, 2010. 3:17 PM
It's looks Cool!!!! how can I make that kind of this?
ilpug in reply to timothycoblentzSep 26, 2011. 6:03 PM
follow the directions! that is what instructables is for.
ILutimus Prime says: Aug 26, 2011. 6:11 PM
Thank you for Your Instructable! Check out my Costume!
http://youtu.be/nDIQgwTlPME
mreflex says: Aug 10, 2011. 8:15 PM
Hiya, i know this is rather old now but i was hoping you could show me some more in-detail pictures of the footwear as i do not understand your instructions and i also don't understand where/how u velcro things to hold them in place (like the legs) any help appreciated
mwoodman says: Jul 29, 2011. 9:42 AM
Primer didnt work for me :( made the spray paint go all wrinkly which is a pity. It must have just been the type of primer I used as everyone else's look brilliant!
mwoodman says: Jul 26, 2011. 3:37 AM
Just about to head out and start scavenging my optimus parts, I'm excited to get going! I'll keep you updated, thank you for this brilliant guide!
hlemoine says: Jul 6, 2011. 1:38 PM
Thank you so much for your instructions. My friend and i made our own Optimus Prime and Bumblebee based on your instructions to go to the new movie! As soon as we walked in we were swarmed by little kids! everyone thought the movie theatre hired us to make an appearance! The workers at the movie theatre loved us so much we got a refund on our movie tickets! They also said we would be featured on the AMC website!! :D i cannot thank you enough
transformers.jpg
ThreeWestCreative says: Jun 21, 2011. 6:12 PM
Oh I just about died laughing at the dancing OP video. hahahaha Great costume and instructable! Now we just need a dancing Skeletor and all will be right in the world. :)
blueandgold05 says: Jun 13, 2011. 12:26 AM
There hasn't been a comment here since '09, so this is probably a long-shot, but...

I've just started this as my "summer project," if you will. I take a lot of pride in having awesome Halloween costumes (this past Halloween, I did Two-Face to much respect), and I want to see if I'm up to the challenge of this masterpiece!

I just started with the chest piece, and I had to make it myself because I couldn't find a box in the right size. My edges are unsightly, and I'm looking for a way to cover them up. I was wondering if there were any tips about spackling cardboard edges. I've never done it before, and I don't want to mess anything up and have to start from scratch.
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