Step 1: A little back-story first (you can skip this if you like)
the pic is Dillon, holding my son Josh like a baby. like i said, he's a BIG boy!
Step 2: What you'll need
dremel or drill
screws and screwdriver
2 bicycle horn squeakers
large washers that will fit on the squeakers posts.
hotglue and glue gun
whatever kind of materials you'll want to cover your arms in
10 bicycle spokes
2 rubber gloves
a cape of some sort
Step 3: Getting started
although one of these pics show a hand already attached, it also shows the fold and the zip tie holding it. you'll want to use several zip ties up the length of the fold for strength.
Step 4: Fingers
whichever method you used, once you've got the fingers stuffed, take a bike spoke (curved end first) and insert it into the finger. this will allow you to position the fingers somewhat when we're finished.
Step 5: Hands
Step 6: Attaching hands to arms
using several of the screws and the screwdriver, attach them to the wrists.
if your hands are a little too skinny to fill the arm holes, use some great foam or a packing material and a little hotglue to attach. you won't see that area in the finished project, so go ahead.
Step 7: Hand holds
i had to fix one of their ears with hotglue... my chihuahua thought it was a chewtoy *eyeroll*
dremel a couple of holes where you want the hand holds to be. (test fit your actors arms for the exact placement of hand holds)
insert the mounting bolts through the holes, add washers and then nuts that came with the squeakers. a good dollop of hotglue will lock them into place and prevent sharp edges on your arms.
Step 8: Finishing up
i chose yellow and black stripes and orange pom poms. yikes, huh? =D
the cape our clown, Dillon will wear is terribly loud (and incredibly AWESOME!)
while at the fabric store, buy 2 packages of velcro patches if you want to attach the cape to the arms. i did this and it is IMPRESSIVE when Dillon throws his arms out. (that is my son wearing it in the pic, he's much smaller then the actor this was made for)
simply place the material on and around the arms, hot glueing and folding it into place. there is no right or wrong in doing this, especially for a clown... i bought like 2 yards of material and had very little left over.
if you're going to attach the cape to the arms, have a model put them on, and line up the velcro. then simply hot glue into place.
Step 9: There you have it
the rest of his costume is a black sweatshirt and pants with painted-on black light reactive circles, and a regular clown mask, also treated with blacklight reactive paints in strategic places (around eyes and teeth)
i didn't get any pics of the reachers in action as i act in the trail as well... but this is the scare that sent a pregnant woman into labor at our trail!