Instructables
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Costume.jpg
 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.

 
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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.
Just finished making this for my little boy, he is beyond stoked. Thanks for the tutorial, such an awesome idea!
minecrasher (author) yesterday
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’t have a clothes steamer available you can use the steam from a standard iron, just don’t let the bottom of the hot iron come in contact with the surface of the foam or it may melt (steam only).

Thanks for this! I'm having trouble with the green foam having "memory" from being rolled up. Any suggestions for (relatively quickly) flattening it out?

loonyzac10 months ago
sweat bro
minecrasher (author) 11 months ago
Thank you all for the comments!
FYI: If you use cream colored ½” 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 “Steve” costume.
sokiboi7811 months ago
Nice job.!!.check out mine what u think? made out of card boards and tape lol Vote if you like ;-)
MonkiMan11 months ago
that is genius
Naro1111 months ago
So creative, like
TwixieMixie11 months ago
So Cool!
kyluddy11 months ago
That's awesome