loading
This year we decided to make Buzz Lightyear and Jessie the Cowgirl costumes.  We started early in September.  We had a ton of fun in these costumes. People were asking to get their pictures taken with us (or trying to sneak them and getting caught so I would pose).  My favorite part of the night was when I felt a small tap on my leg and a tiny voice that said “Hi Buzz Lightyear.” It was a child about 3 years old and he wanted his picture with me. Then said “Thanks Buzz” and got scared and ran back to his mom. Just a side note:  If you have things that look like button on your chest, people will try to push them.

Jessie:  Her costume was home made chaps cut from a ruined pair of pants and fabric glued.  The shirt was a button down.  We painted the yellow detail with screen printing ink (fortunately we had some from shirts we made).  The red detail is rickrack shaped into patterns and glued on (and later safety pinned).  She bought the hat black and covered it in wood glue to make it paintable.

Buzz:  I made my Buzz Lightyear costume.  This was more time consuming.  The chest piece and upper leg armor was made out of 55 gallon drums.  I used the natural shape of the drum to my advantage and then used a heat gun to mold it to shape.  The shins are hockey shin pads.  The arms were made out of 3 gallon ice-cream buckets from the local ice cream shop (thanks haunted depot).  And of course the dome.  I ordered the dome online. It is a 16” plastic globe meant to be in storefront displays filled with gifts.  The dome was attached with hockey pucks and simply orange container tops.

Step 1: Jessie's Wig

Jessie's wig was made out of yarn.  We had my mother in-law help us with the fitting and sewing.  They sewed the part and  braided it so it could be taken on and off if need be. On a side not.  The braid is really thick so make the strands extra long and cut it later.

Step 2: Jessie's Chaps

My wife took a pair of old jeans and we traced the chaps shape on them and cut it our.  She then glued the material to the pattern. Once it was dry she glued the chaps to the front of a pair of high wasted jeans.  The belt buckle was made out of yellow fabric on a foam board.

Step 3: Jessie's Shirt and Hat

The shirt was a button down shirt. We used screen printing ink for the yellow.  The red details is glued and pinned rickrack. She bought the hat black and covered it in wood glue to make it paintable.  It took three cans of paint but it gave it a plastic look.  Then it was just a matter of drilling holes and looping the strings.

Step 4: Buzz's Chest

This was more time consuming.  The chest piece and upper leg armor was made out of 55 gallon drums.  I used the natural shape of the drum to my advantage and then used a heat gun to mold it to shape. I mounted the chest on a pair of football shoulder pads.  The paint is Krylon bonds to plastic paint.  The paint job was not perfect so I decided to "battle scar" it and make it look like he was worn or in a battle (Perhaps with the evil emperor Zurg or from getting bounced around in the back of a pizza delivery truck).  The arms were made out of 3 gallon ice-cream buckets from the local ice cream shop (thanks haunted depot).  And of course the dome.  I ordered the dome online. It is a 16” plastic globe meant to be in storefront displays filled with gifts.  The dome was attached with hockey pucks and simply orange container tops.

Step 5: Buzz's Legs

The shins are hockey shin pads cut up and flipped over (it was to give it the flared legs buzz has).  The boots are spray-painted snowboard boots I had laying around. I also battle scared these.

Step 6: Buzz's Details

I found decals of buzz online and modified them to fit my suit. I printed them and mounted them to plastic and mounted that to the suit.  Be careful when gluing things to painted plastic.  It will rip the paint off and fall off easy.  I had to scrape away the paint in order to make it stick.

The laser was made from a kid’s toy that lit up in the Walmart checkout line.  They are everywhere right now.  I also made a star command communicator by mounting my phone on my arm and attaching a speaker to my chest.  I had a playlist of all buzz’s quotes and “you’ve got a friend in me
<p>made it!!!</p>
<p>That Looks awesome. Great jobs!!</p>
Hey! Trying to PM you regarding this AMAZING work (but not getting through)...I work for a movie site and have gotta talk to you! :D
<p>Thanks so much! I just sent you a direct message.</p>
<p>You are amazing!!!!!! Very Talented</p>
<p>Thanks for the kind words. This is one of my favorite projects</p>
<p> I wish you would have made a &quot;how to&quot; video with step by step instructions. . .I would have DEF bought it. AWESOME by the way, just AWESOME!</p>
<p>I can't seem to find where to buy that globe. Do you by any chance still have the website? Thanks for your time.</p>
<p>Here's the thing. When I bought it I was able to buy just one. Now it looks like they have a six piece minimum. Also Mine is a 16&quot; globe and all they have is an 18&quot;. I would try calling the company and see if they will ship you just one. </p><p>http://www.sparkledecor.com/clear-spheres--18--dia--60-gauge---each--.html</p>
Thanks for replying back! I will definitely give them a call.
Did you use fiberglass to make the green chest pieces that are attached to the white piece?
<p>Where did you get the purple headsock?</p>
Amazon. I just searched for purple Balaclava.
love the costumes! where did you get the dome for the Buzz Lightyear helmet? <br>
The dome was an acrylic display globe that department stores use during the holidays. They fill them with gifts and hang them in the windows.
apologies, just looked again in a little more detail
Yeah. The arms were easy. I used ice cream bucket for the plastic. the upper arm attached to the chest. The lower arm slid on and stayed put with elastic. The elbow was done with just some children's elbow pads. Just a heads up. Find the smallest pads you can. You can see that I am wearing larger ones in the outdoor pics and they look to bulky. I am wearing smaller ones in the indoor pics and fit better under the arms.
May I ask how you did the arms? Brilliant instructable!
hi i was wondering how you did the green part of the chest and did you have to use 2 55 gallon drums to do the front and back part not including the jet pack part, thanks
Also for the jetpack I used PVC and a much thinner plastic from ice cream bucket that I got for free from a tourist shop.
how did you attach it to the football pads?
I drilled holes into the pads and used long bolts to attach the chest. It allowed me to make adjustments so it had the right spacing away from my body.
Yes. I used two drums. The top and bottom of the drums were different so I had to use two. I grabbed a bunch of reference photos and Started scaling it. I knew that Between the hinges of the hood was going to be 16&quot; because that was the size of the globe. From there I would measure sizes off of photos I could find. If the drums are the same size it is mostly a matter of making a flat template and tracing and cutting. I gave myself extra plastic to curl under the bottom and give it the bubbled look. <br>Hope that helps
Wow! Just wow! My son and daughter freaked out when they saw this! LOL
A-maze-ing! Love it, VOTED!
Thanks. We appreciate your vote!
You guys did a really fantastic job, especially considering what you used for materials. Fantastic!
Thanks! That really means a lot. It was my first big costume build I learned a lot and can't wait to try something else. The plastic was tough to work with but was able to withstand the punishment of people trying to slap the buttons and flip down the hood.
It's always a challenge to make a costume crowd proof! One time I had someone run up behind me and rip my proton wand clean off my Ghostbusters proton pack.
I forgot to mention that the whole chest piece was mounted on to an old pair of football shoulder pads. You can see it sticking out the sides.

About This Instructable

42,895views

105favorites

License:

More by nbehling:Nickelodeon TMNT Two Dark knights. Buzz Lightyear and Jessie the Cowgirl 
Add instructable to: