If you think the costume is magical or creepy...please vote for me in the Halloween Costume Contest: http://tinyurl.com/9nnz7bq.

I start every costume creation by finding an example that is done often, but not to an extreme level. I saw that the only unicorn costumes online were baggy store bought suits or a horn duct taped to someone’s forehead. I knew I could do better and add an X-Factor like fog snorting out the nose.

Step 1: Foam foundation

Create your foundational foam structure. I recommend using a combination of the dense core home foundation insulation and expanding foam (low expansion and high expansion). Cut the foam by scoring and breaking. Glue it together with Gorilla glue and definitely use clamps. You can insert pieces of wire at this stage to reenforce joints. Don't rush the gluing process and let it cure for a solid day or two.

You can then use your expanding foam to get a bulk structure for rounded areas.
<p>Hey! I love your costume, but I REALLY love the effect of the compressed air. I am trying to make an Avatar the last airbender Zuko, and was hoping I could use a similar effect to make it appear like I am shooting fire out of my hands, but I'm a little apprehensive about possibly burning my skin off, as I would have the nozzle likely near my or on my person.... Any ideas as to what I should do? </p>
<p>Like it!</p>
U no how would u no it burn u did u get burn by it
None of the liquid came out which is what would irritate your skin.
<p>at least you knew what was talking about I came back and I read my comment and im like what was I thinking it sounded like I was a little kid</p>
Great job, I wanted to make a horse.... I guess this will work fine.
Wow...what a large...horn you have there
Hi.. How were you able to see out?
I can see out the mouth and then the entire bottom of the lower jaw is wide open so it was super easy to see where I was going. The main annoyance was the weight. If I were to do it again, I would build a light metal armature using plumbing strapping, a bike helmet, metal wire that can be hot glued into shape, paper mache, and then upholster. It would cut weight by about 75%. <br> <br>I'll be posting the techniques in a couple days when I add this year's Dragon costume.
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
Thanks! Hoping for the laser cutter tocreate something even better next year!
OOH that would be awesome!
This is fantastic!!!! Very well done 5 stars and a vote for you!
Yes. Yesyesyesyesyes.
I love unicorns... <br> <br>but I'm gonna have to file this one under creepy.
OMG SO DOPE! I wish I was friends with you
Unicorns are for gangstas.<br> <br> <a href="http://www.youtube.com/watch?v=-9d8Wn1Za4o" rel="nofollow">http://www.youtube.com/watch?v=-9d8Wn1Za4o</a><br> <br> A great instructable! You are very creative.
Pretty cool costume.
God Job LOL :P

About This Instructable


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Bio: I am a foam fabricator and own a costume and prop design company called Partybot Designs. I take on commissions of any scale from cosplay ... More »
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