Optimus Prime Costume

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Picture of Optimus Prime Costume
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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tacosmith4 years ago

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
nmoraga tacosmith5 months ago
hi , i would really love to know the step by step in doing your childs costume. please contact me asap. :D more powers to you
Tacosmith, great job, especially since it had to be scaled down tremendously...really awesome. 
Thanks for the great instructable!
Doctronic2 years ago
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.
That's awesome, this helped me a little. what did you put in the leg to keep it on you shin? foam board?

Know its a bit late replying.... 2 years I think. lol! But I used thick foam on the legs and let it 'hug' the leg and prayed that gravity didn't take over. If I was to build it again, I think I would of used a different method.

post your own instructable rather than clogging this up.
dannyeurena (author)  frisbeechamp19838 months ago
It's been a while since I've posted but I don't mind the extra traffic. It's amazing to find others as passionate as I, so "clogging" is welcome.

Been awhile I've been on here too. But thanks for the thumbs up :) Unfortunately I've had to retire Prime due to wear and tear and is now sitting as a demo piece in my comic store for people to look at. I've now moved on to doing a Steampunk Prime and few other things. I've used the Prime blue prints as the base and worked out a few problems. Sorry if I was 'clogging' but I guess some people can't handle the awesomeness! ;)

NO, really get this off here, and post a photo 'ible!
i bet the guy in the assassins creed costume felt like a loser standing next to OPTIMUS PRIME!!!!!!!!!!
Eireannach made it!1 month ago

Awesome instructions!

Eireannach1 month ago
cbeatty15 months ago
Thanks for the inspiration, made my first Optimus costume, and blaster! This was a lot of cardboard carving , let me tell ya! And it's true glue gun burns freakin hurt! Lol!! But just wanted to say thanks for the pics and the info, made my Halloween fun!
25 H, 10:07 AM.jpg25 H, 10:07 AM.jpg
Zerofi5 months ago
Another one.... thanks for the tips and inspiration.
nmoraga Zerofi5 months ago
hi mind to post your kids step by step costume. optimus prime. thanks
smcshinsky5 months ago
Thanks for the great instructions. I had a blast making this.
aday115 months ago
I just want to say thank you so much for posting this awesome picture.. As you can see I made Optimus for my son who is almost 7. I didnt use any of the diagrams, etc.. I just went by looking at the picture of the finished product. And He won Best Handmade Costume this year. And If it wouldnt of been for the main picture you posted, I dont believe it would ever of come out as good as it did.. You had great detail, and all the right things. Again Thank you. Hearing him say "I Love it sooooo Much, Thank you, you are the Best Mommy ever" was worth all the time invested. Which was around 100 or so hours. Next year he wants to be an excavater.... LOL
bwoolard6 months ago
I'm wanting to build one. Where do I find the patterns? I can't find them anywhere
ablec16 months ago
trying to build one now. Thanks for this build. Iam going to also build my son a halloween costume! I love G1 Prime!!!!
jeffphares8 months ago
Just wanted to say great job! I'm starting on one myself. I'm making my out of EVA foam and it's going to have a war "weathered" look to it. You did a fantastic job man!
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.
kfh99m Jollytime7111 months ago
I like the suit. How did you make the gun?
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!
ybravo21 year ago
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 :)
Eireannach1 year ago
Awesome instructions! Took me every weekend for 2 months but I finally finished. Here is my Optimus!
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!!
This is my Optimus prime costume so far!!
transformers optimus prime costume.jpg
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
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.
Team33132 years ago
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


Anything that you could give us so that we can have an easier time building it. Thanks man, your great.
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?
Upon looking at your design I was wondering if you had demensions to follow at all?
psmarie2 years ago
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.melton2 years ago
Thanks for the instructions. Here's what we did, Optimus and Megatron. I may post instructions on Megatron later.
chuckmccue2 years ago
I used a lot of the instructions on this page. It came out great! Thanks!!
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!
I could imagine doing that, all the same I CAN'T STOP LAUGHING!!! And a TRANSFORMING BB costume?! Pure AWESOMENESS!!!

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