Buzz Lightyear costume

I built my firts Buzz Lightyear costume,  back when Toy Story 2 came out, for my neice and nephuew's birthdays.  Now that I have two boys of my own I decided to revamp my Buzz for the re-release of 1 and 2 in theaters. 
Buzz 2.0 took a total of 14 day from start to finish.  I hope this instructable helps  you with your Buzz project.

Step 1 Materials and Tools needed

Materials list:
Chest:
Cardboard barrel 55gallon
foam board (foam core) qty will vary based on your size

Torso:
Foam Pipe insulators(4-5)

Cod piece:
Cardboard Barrel 5 gallon
foam core 1 sheet

Legs:
2 Large construction cones

Feet:
Old Pair of shoes(slip on shoes will work best)
Foam sheet
Foam core

Arms:
Two mini basket balls(shoulders)
Cardboard tube(biceps)
two mini gym ball (elbows)
Small construction cones (fore arms)
rubber gloves

Paint : White, Green, Purple, Gray, red, dark green, blue
old desk calendar 2'x3' paper
painters caulk

Tools:
Razor, Hot glue gun, Caulk gun

Comments

[shaneb24]

you said "Cardboard barrel 55gallon" Where would one find suck a thing?

[Rich Morgan]

I found mine at a local Hardware store. It had a sweeping compound in it . I asked them what they do with the barrels when they are empty and they gave it to me for free. You can also purchase them at stores like Rand supply and u-line. both of these suppliers are on line. You could use a trash can to accheive the same goal. I like the barrels just because they are more durrable than a trash can.

[paddyradford]

Hi Shane, I've used a black plastic dustbin, seems to be pretty effective.

[mom2beauties]

It looks awesome, you did a really good job. Anychance you'd be willing to rent it out to me. My son's birthday party is next week and I just don't thing I could do as good a job as you did. I hired someone to play him, but if you live close you can come over in it. I have no problem paying, but don't want to pay the 100 that actors are asking.

[mary candy]

OMG!
I L-O-V-E it!
Shame you didn't take all the pic , you making the Buzz.
But it is really really wonderful.