A couple things before I get started... this isn't an Instructable on sewing or welding. I don't claim to be an expert or know all the best practices. I know enough pull off projects like this and that's about it. Short of emergency hand stitched repairs on clothing, this is the most adventurous sewing project I've taken on. I've done plenty of welding but mostly just fudge my way through it on the fly.
Step 1: Materials & Tools Required
(6) 9 x 12" sheets of white felt - 3 for $1.00 at a craft store
Small scraps of muslin - free from my Mom's sewing room
Black speaker cloth - left over from other projects
50 yds of black crochet thread (about 1/16" diameter) - $1.89 at Jo-Ann's, probably only used 3-4 feet.
Heavy duty brown thread - from the kitchen junk drawer
Heavy duty white thread - borrowed from Mom's sewing room
(4) small snaps - from a mini sewing kit also in the kitchen junk drawer
(2) buttons - same as above
(2) 3" diameter Styrofoam balls - $4.99 for 6 pack at Jo-Ann's, plenty of left overs for other projects.
Plain white mask - $3.99 @ Spirit Halloween Store
Mid length black wig - $12.99 @ Spirit Halloween Store
Suit jacket - Has been part of my halloween wardrobe for years. Been used for many a costumes but originally bought on the small side for Frankenstein.
White collared shirt - $5.99 @ the Goodwill
Black dress pants - from my closet
Black dress shoes & socks - also from my closet
98' of clothes line rope - $1.00 @ some dollar store
Straps for cross support brace (optional) - borrowed from my Hollywood F1B strap on bike rack
(2) 36" x 1/8" cold finished steel round bar - $2.07 ea @ Lowes
(1) 36" x 3/16" cold finished steel round bar - $2.47 ea @ Lowes
(1) Simpson Strong-Tie RTU2 U-anchor - $0.89 @ Lowes
(1) pkg 3/16 x 1-1/4" zinc plated fender washers - $1.15 for a 4 pk @ Lowes
1/2" x 2" wood for cross - free with purchase of house (previous owners left lots of new trim boards, wood, building supplies, etc.. in garage when they moved out.)
(4) 1-5/8" drywall screws - from my drawer-o-hardware
Most people will have the majority of these tools on hand. Anything I had to buy or borrow for the project is noted below. The back support for the cross would be tough to do without a welder but there is probably a way to pull it off. Maybe with lots of duct tape? Duct tape makes every project better.
Upholstery repair/gigantic needle - $1.89 for a variety pack at Jo-Ann's
Safety pins or straight pins
Sharpie or fabric pen
Styrofoam glue - $3.99 @ Jo-Ann's
Multi-tool or pocket knife
Lighter or matches
Hammer or mallet
Cordless or corded drill
Hand saw or power saw
File or sand paper
Metal cleaning chemical - I used White Lightning Metal Prep.
Welder (borrowed from my work)
Gas - bottle 75/25 steel mix (borrowed from girlfriends dad, work only had full size bottles)
Flame resistant clothing