This is a quick and easy project that will take approximately 3 hours or less to complete depending on how detailed you want to make it.
 We purchased the ½” thick green upholstery foam from Jo-Ann’s Fabric & Crafts for $11 a yard. Use a Jo-Ann's printable coupon from (www.joann.com/coupon) when you purchase the foam and it will only be about $6 a yard. The t-shirts we used are plain light blue cotton Fruit of the Loom t-shirts that can be purchased from Target or Wal-Mart for about $4 each.

Step 1: Materials Needed:

1. The upholstery foam is green ½ thick and “Jo-Ann’s Fabric & Crafts” sells it in 2.5 yard by 24” lengths/sheets (depending on arm length 2.5 yards is enough for a child’s size costume).
2. Low temperature hot glue sticks & gun (regular hot glue may be too hot and melt the foam).
3. A yardstick to use as a straightedge or a fabric cutting board to keep your foam cuts perfectly straight.
4. Two (2) color-matched cotton light blue t-shirts (one to cut/cover the upper foam arms & one to wear).
5. One (1) fine point felt-tip light green “sharpie” permanent marker to draw out your grid lines.
6. One (1) black & at least three (3) shades of green permanent markers or paint pens with large tips (bigger the tips the better) to color in the grid squares on the foam in a random green pattern.
7. Exacto-Knife or box cutter with new blades (dull blades will tear the foam and keep you from getting a clean straight cut).
8. (Optional) two (2) small pieces of black vinyl window screening or black nylon stockings to blackout the eye cut-outs from the inside the head.
<p>Thank you so much for the instructions. I followed your specifications and everything turned out great. My only advice is when buying the shirts, buy one in your child's size, and the other as large as possible (I bought two small shirts and had to to piece together scraps to make sleeves for both arms). He got a ton of compliments. :)</p>
<p>Thanks for the instructions. I used different dimensions for everything, but basically followed every step you posted. I did sew the arms to the t-shirt at the top and put a stitch in at the bottom, so they wouldn't slip off. </p>
<p>ooo, you did a body too. Nice! </p><p>I thought of doing a body but decided it would be too awkward to move the arms. How did it turn out? </p>
<p>Thanks for this! It is an awesome idea. </p><p>I make a Steve for my son and adapted it for a creeper for my daughter. The local bargain fabric store only had 1&quot; foam so I had to adapt it a little, but the instructions posted were clear and easy to tweak. Fantastic Instructable!</p><p>The sword is store bought though (birthday present from my mom to her grandson).</p>
<p>If you have a little kid, I highly recommend getting an XL shirt to make the sleeves! I got a medium thinking that that would be enough. </p>
Just finished making this for my little boy, he is beyond stoked. Thanks for the tutorial, such an awesome idea!
You can steam curled pieces of this type of foam on a flat surface to straighten it out or to remove dimples. If you don&rsquo;t have a clothes steamer available you can use the steam from a standard iron, just don&rsquo;t let the bottom of the hot iron come in contact with the surface of the foam or it may melt (steam only).<br>
<p>Thanks for this! I'm having trouble with the green foam having &quot;memory&quot; from being rolled up. Any suggestions for (relatively quickly) flattening it out? </p>
sweat bro
Thank you all for the comments! <br>FYI: If you use cream colored &frac12;&rdquo; foam in place of the green and use shades of brown markers/paint pens you can tweak these instructions a little and easily make this into a &ldquo;Steve&rdquo; costume. <br>
Nice job.!!.check out mine what u think? made out of card boards and tape lol Vote if you like ;-)
that is genius
So creative, like
So Cool!
That's awesome

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