What that means for me is that I'm the one left to do all the sewing and Halloween costume-making. This arrangement works out well--she likes to cook, and I like to make stuff and eat well. It's a happy marriage.
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 cut, shaped and sculpted as I went.
Step 2: Chest piece details
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
All the pieces were hot glued in place, and the entire structures were primed and painted.
Step 4: Arm pieces
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
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.