Halloween gets me pretty gosh darn excited. It does however present some problems for me in the months of September and Octabober. That's right.... I said Octabober. That's because I have been working on this build day and night for over two months. I'm losing it.

The only real problem with building a costume each year, is the fact that one must outdo oneself. Last year's Chucky vs. Toy Story costume won me a respectable third place in the epic costume category. You'll see pictures of me using the third prize cordless dremel in this year's build. I knew that thing would come in handy.

So here I am.... Halloween is over and I'm still obsessed with the Holiday. And yes, it is a holiday... better than Christmas in my humble opinion.

Before you start, I should post a few bulletins for your benefit.

  • My ultimate goal is originality. I try to make a costume that no one has ever done before. No Ironman suits for this guy. Sure people have done Bowser before, but not with a castle, and not with automated toys. Muahahahahahah....
  • I'm hoping to move up the ranks this year. Yes, this is my blatant plea for your vote and consideration. My prizes are for my students and they will surely benefit from a laser cutter. Wink wink.
  • Please use my instructable for inspiration. You probably don't want an exact replica, and you can probably build it better than I did anyway. I know there are a lot of things I would do differently, if I were mad enough to try this one again.
  • Please understand that I am a high school teacher and I am lucky to have access to a number of great tools and machines. This can sometimes be frustrating for the average instructabler, but I assure you, there are ways around everything. I 3d printed horns, but could have easily made them exactly one hundred different ways.
  • I took a carp load of pictures.... yes I said carp. I'm sure you'd rather follow my detailed pics than read chapters of my boring scrawl. I've done my best to annotate pictures where you might be wondering what the heck I'm trying to show. Please ask if there is something you're not sure about.
  • I've decided not to start with the typical list of materials step. It would be long and overwhelming to start with. Please decipher materials from each of my steps and ask any questions if unsure. I think I've covered everything.

Here's a video of the finished costume for those of you that can't wait to see what it's all about.


Step 1: Design, Sketching, Modelling

Always start with a sketch. The first image shown is the very first sketch I made when I decided that this was what I was going to build. The idea certainly evolved, but primarily stayed true to the initial concept.

Before you start to model in 3d it's helpful to make a full size drawing or cardboard mock-up.
<p>would you ever consider selling this costume?</p>
Hi great costume It's the most realistic bowser I have seen :D. <br> <br> I really need to make a bowser costume for a Beaver Scout camp in May. I have 2 questions. First what size and type are those sheets of foam you used for the mouth? <br>Secondly could you recomend any way of cutting it other than the hot knife as I dont have access to one? <br> <br>
<p>thee are instructable on how to make hot wire knives. good sharp knife would work but make shure you wearing proper gloves tho.</p>
This is awesome!!!
Holy smokes, that is awesome. I admire the level of detail and ingenuity you demonstrated in animating all of the characters. The castle detail is also very impressive - Excellent work, I'm sure that costume is the main attraction for all costume parties - Well done
Congratulations on Second place! Your creation is very impressive!
Thanks! Bowser had a pretty good Halloween I'd say. You did a great job too!
One of the best I've ever seen here! Congratulations!
Ok, I'm a newbie to instructables...as in I literally started a few days ago. And...I...this is...I mean...WOW. Just...THIS IS SO FREAKING AMAZING I CAN'T HANDLE IT. Totally voted. TOTALLY. VOTED.
Wow thanks! That was a pretty great comment!
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
Thanks! Fingers crossed.There is some really stiff competition as I'm sure you are aware.
Hello kind sir who I am not acquainted with in anyway. I highly enjoyed this Instructable. I would offer some constructive criticism, but this is too darn good. Keep up the good work. I hope one day I can produce such fine work. Keep up the fine work. <br>Your's truly, <br> <br>Mr. Chunks
Now that is just <em>awesome</em>.
Thanks! Can I trade in my k'nex gears for some of your servos? Your helmet is amazing!
Thanks! Everything is better with servos... :)
Best anything ever. Of All Time.
Well said Sir!
This is one of the sickest things I've ever seen! Great job Mr. Noack! Definitely got my vote. :)
Thanks! Is this who I think it is?
Mr Noack this is the siiiiiiiiiiiiiiiiickest !!! I almost feel sorry for pestering you to finish, i didnt realize how all-out you were going ! I cant wait to see it all move in real life. Im honestly voting 'cos i like it, not 'cos you determine whether i get three credits this year :D
Absolutely amazing! You've got my vote.
This is fantastic! <br />I love seeing the concept sketch included in the writeup. All those automated toys moving.. so great!
Thanks! It's always interesting to see how the finished product compares to the original idea.
Amazing! Love the lights, all of the moving parts. Very professional!
Thanks Mom, couldn't have done it without you:)
Simply fantastic!!! All that time and effort was totally worth it! You got my vote, good luck!
Thanks a million! I think I'll take one day off and decide what to build next. Can't wait until next Halloween!
That is so awesome!!! So much work, but it looks like so much fun to wear and play with :)
Thanks! It was a lot of fun to build and I feel like a superhero in that jacket.I might wear it this winter.

About This Instructable


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Bio: I'm a High School Technology teacher with self-diagnosed Creativitis, a disease that doesn't let my brain sleep. I spend my days trying to ... More »
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