My son wanted to be Emmet from LEGO MOVIE for Halloween so I looked all over for the costume @ every retailer imaginable, after I had run out of options I decided that I would try to make his costume at home. The head and hair are just a sheet of dense foam. I cut out many of the needed diameter and glued them all together. after that had died I used a coarse wood file to start shaping the foam to my desired shape. I then coated it in resin and painted it. The whole body is nothing more than precisely cut junk cardboard scraps taped together and covered in resin.

Step 1: Measurements of the Person That Is Going to Be Wearing It Are "key"

First thing you need to do is get some measurements. You want the costume to fit the person you are building it for. You can't expect to build it and just hope they can fit in to it. Get measurements of head, shoulders, chest, mid section, waist, legs, feet, etc.. I took every measurement I made and added one inch to it. That way the costume would fit "snug". I found a flat piece off cardboard and started drawing out my measurements. I decided how wide the waist needed to be to look the most "lego like", then based everything from the waist down off of those measurements. Having a lego figure with you will really help with this step. I drew it out with tabs so that it didn't have gaps on the corners after I cut it out and folded the cardboard.

<p>Hello how so you apply the fiberglass resin? Could you apply this to paper/cardboard items to stiffen it? Is this water resistant?</p>
Did you keep the tape on the whole time, or did you take it off? Also, did you use fiberglass resin right ontop of the cardboard? Thank you, trying to make this for my son for Halloween.
<p>very good, i feel make it so easy .</p>
Thanks for the guidance! It wasn't easy, and it was a bit awkward for him to wear; but it was a real hit!
<p>You put fiberglass resin directly on the foam? Won't that eat through the foam?</p>
When you coated the head with fiberglass resin did you just brush it directly on the foam or did you lay a cloth on the foam and then brushed the fiberglass resin over it? If so does it have to be a specific type of cloth?
<p> the belt is pretty much a T shape that matches the curve of the top of the legs. The legs are actually worn by suspenders which carry the entire weight of the costume in order to keep the legs from dragging the ground. You can contact me via email @ codybrown2003@gmail.com then I can easily send pictures in </p>
<p>I'm having a hard time figuring out the crotch and belt. Could you explain or post pictures of how it all connects?</p>
<p>I'm trying to make this but having a hard time sourcing the foam. Any resources online or a foam type/name I can search for?</p>
You can get the foam in sheets at home depot in the flooring section where the carpet padding is...its polyurethane foam
<p>Thanks. When you used the fiberglass resin, did you use the cloth to reinforce the fiberglass or just the resin?</p>
There is no fiberglass on this costume. I used cloth in place of the fiberglass for a smoother finish
<p>Fiberglass cloth or fabric cloth?</p>
<p>Sorry for all the questions, its my first time working with resin. So rather than using fiberglass in the resin, I should use something like 3M 499 Fiberglass Cloth with the resin?</p>
<p>What specific brand and type of primer was used for the foam and cardboard before painting? Did it help smooth out any indentations in the foam? Thanks!</p>
<p>You mentioned that his vision is through the mouth? Looking at the final photos I see a painted mouth with teeth and tongue. I cannot see any screening used or a cutout in the mouth. Would have like to seen a video of this costume in motion. The legs, hips and torso are seamless which would make leg movement difficult.</p>
Herei just took this &quot;seamless&quot; photo just for you. Now which parts are seamless???
Hello, I was wondering if you can maybe send detailed leg info if possible. I'm having a hard time seeing that photo up close.
Here's a few from two different Halloween contests. I didn't think to take video.
here's a better photo of the mouth
<p>What kind of fiberglass resin did you use? This is amazing. I am doing Batman and the joker.</p>
I just started my son's costume, but trying to figure out how u did the legs...
How long did this take you? This is absolutely amazing!! Great work!
SUPER DAD not mom, and thank you!
This is amazing! You pretty much won the father of the year award with this. Very creative and dedicated.
<p>what an absolutely fantastic outfit. Could you please tell us what type of foam you used to construct the head? Is it the same from that people use for flower arranging?</p>
It is the same kind of foam they use in flower arrangement but purchased in a 4x8 sheet at the fiberglass facility I work@. People use it for forming molds.
<p>What kind of foam exactly did you use for the head?</p><p>PS: Very nice job!</p>
Wow...that is amazing at first I thought it was a real Lego man!:D
<p>Emmet -- I just wanted to tell you that if I had been a judge in the Heroes/Villains contest, you would have gotten my vote for first prize. This build looks great, the instructions are easy to follow, anyone can do it, and I would wear one.<br><br></p>
Thank you very much! That means a lot to us! We were really disappointed in the results as well. Maybe next year...
<p>love the costume! just wondering if you could provide some instruction on how you created the hands? </p>
I apologize! I didn't realize that I hadn't put the hands in my instructions. the grey rod inside is a plastic fitting I found at the hardware store that fit snug inside the pvc. I used that same loctite glue to glue everything together and used silicone to make a smooth edge between the hands and wrist before painting.
<p>Thanks. Seamless meaning there is no visible gap while standing still. The human leg naturally bends which would lift the Lego leg up and forward causing it to crash into the hip and torso. Just trying to understand your mechanics.</p>
Oh okay. Well it's identical to the way a lego figure moves. The legs only move at the hip but the legs are hooked to suspenders which makes them float about 3/4 of an inch off of the ground so that they don't drag. the top of the legs are cardboard cylindrical concrete forms which allow the legs to pivot much like a lego figure does. I could have given him knee joints to make walking much easier but since he was a lego I thought it was better suited to move the same as a lego
<p>your son is very lucky to have a father like you whos willing and have the kill to create such perfect costume for him. </p>
He won the costume contest here in the town we live in, but I didn't get to share Halloween with them because I had a stroke the morning before Halloween. I was in the hospital for ten days. It was great news to hear that he had won though! Thanks for all of your positive feedback!
<p>every thing about it is awsome</p>
<p>How does he move his legs?</p>
just like a lego man moves his legs
Ok so the legs and crotch aren't fixed? It was hard for me to tell from the pictures. I take it he had no trouble getting around on Friday huh?
No the legs and crotch are separate and the crotch has bolts that attach it to the upper body. The legs have staps that go over his shoulders underneath it all do that the legs are just slightly suspended so that they don't drag the ground
<p>You did such a good job you can't even tell they're separate pieces!</p>
Outstanding! The hair in particular is BRILLIANT!
<p>Amazing costume! The one thing I would ask for is more detail in the steps and pictures. Such a great job - I would love to try to put that together for my boy.</p>
<p>Thats awesome! I have to make sure my kids don't see this, they will want me to build them these every year :) . Nice work. Are there eye holes? Can he see?</p>
you look though the mouth.

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