Buzz Lightyear and Woody Costumes





Introduction: Buzz Lightyear and Woody Costumes

This year (2008) my kids wanted to be Buzz Lightyear and Sheriff Woody. This instructable focuses on the Buzz costume because it required a more unique, creative approach.

Step 1: Chest Piece Structure

I borrowed one of our garden planters and used it as a mold to build up the basic chest structure. The chest piece is made of cardboard, duct tape, masking tape, hot glue, and paint.

I cut, shaped and sculpted as I went.

Step 2: Chest Piece Details

Details were added to the chest piece with more cardboard, foam, and tape.

The jet pack and wings were also built at this time.

I spray painted the entire thing white, and added details with colored craft paint. The entire thing was given a coat or two of lacquer to make it shiny.

Step 3: Leg Pieces

These were made from two small sports cones, cardboard, and the bottoms of four yogurt cups.

All the pieces were hot glued in place, and the entire structures were primed and painted.

Step 4: Arm Pieces

The upper arm pieces were made from pieces of flat cardboard that were curled and glued together to form a tube shape.

The forearm pieces were made from cheap plastic cups--the kind that kids get at restaurants. They were cut and shaped with a sharp utility knife and scissors.

Details on these pieces were done with sharpies, paint, and colored pencils.

Step 5: Hood

The hood was made from purple polar fleece.

I had to make up a pattern for this part. The first attempt was close, but not quite good enough. So I added a little where needed, and the second attempt gave me something better.

Step 6: Finished Costumes

Buzz's costume was completed with a black sweatshirt, and white pants.

Woody's costume was fairly simple, although the shirt, vest, buttons, star, belt, holster, and spurs had to all be made. The boots were originally pink, and the hat was orange. Some brown spray paint fixed that.

The costumes were a hit with my kids, and all the neighbors got a kick out of them as well.

I was the popular Dad this Halloween. Boo-yah!



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    You are awesome. My kids want me to create an awesome buzz lightyear costume for them like the one you are showing here. My son thinks your creations are pretty cool. Thanks.

    im jared i was wondering can i buy this buzz suit from you if i can :)

    Hi Jared,

    Unfortunately the suit is not for sale. But I'm glad you like it!

    That is just AWESOME! Thank you SO much for posting. You did a FANTASTIC job!!!

    Excellent tutorial. Thoroughly enjoyed making an adult sized version for myself and was a hit at this year's party. Thanks!

    The award of best dad goes to....

    A slight modification here and there, maybe a size up. Looks good bro!
    Im bein hardcore buzz 2013 =D

    I am so going to make this for Halloween this year! But I'm stumped on how I should make the base structure... I'm 5"6-7, and I can't find a planter big enough for my torso. Does anyone have any ideas on how I can make it? Or would I just have to go free hand... I've considered those big buckets, but they don't have the tapered shape, just a straight cylinder. Any ideas would be appreciated! And kudos to your chestpiece!

    If I were to make one for me, I'd go freehand like you say. You should determine the circumferences you want both the top and bottom of your chest piece to be, and decide on a height. With some basic math you can figure out the dimensions, and how many cardboard slats you will need to cut out and tape together to make the basic chest piece shape. I hope that helps. Good luck! Let me know how it turns out.