Picture of Halloween 2007 -
Inspired by the 1984 hit. It took about 3 weeks to make.

Step 1: Dummy

Picture of Dummy
I apologize for not having full instructions. I started to document then that fell by the wayside as I got into the building of it.

I first built a duct tape seiwng dummy by having my wife and daughter wrap duct tape around my torso. then we cut it up the back and stuffed it. I mounted it and had a good dummy on which to build the costume. The picture below shows a long sleeve shirt (costume inner liner) surrounded by a plastic frame I built out my my kid's K'Nex pieces. Worked better than expected. On this I mounted 1/4" carpet padding foam and then I stuffed poly fil under that. Wrapped the whole thing in nylon and sewed away.
WhimWham5 years ago
I love this costume!  Great job! 
Costume's are fun to make but I wish they could be reverse enginered!  I was Spongebob and my daughter was Gary one year.  Her costume was so heavy that she couldn't get up the steps to trick or treat....and I was no help because we played music in my costume, I had tiny eye holes, and I could hardly move!  I was basically blind, deaf, dangerous and unable to help my gimpy snail! 
But darn it , we looked cool!....Not as cool as you though, because yours is just awesome! =)
I don't know whether to run away screaming or hug it.
Bartboy5 years ago
KNEX!!!! Yay!
lax12127 years ago
you could fill the body with air balloons
Williz7 years ago
Heh bit silver for the Puuf man :P But yeah cool suit :)
jongscx7 years ago
...how hot was it in that? I mean being sandwiched between nylon and foam... I guess the torso air-space helps, but the legs and arms are probobly direct contact to skin, no.. either way, very nice.
NavySWO91 (author)  jongscx7 years ago
Honestly, the body and arms were not that bad.. it was the styrofoam head that killer... had to lift the front up every couple of minutes.
mod a PC fan to run off of AA batts and vent it in the back?
Woooo! That looks really good!
Brennn107 years ago
That is a really awesome costume. Too bad you couldn't do full instructions, but very nice job none the less!
NavySWO91 (author)  Brennn107 years ago
Yeah. I apologize for that. I did the "Operation" Instructable last year and started out to document this too. Unfortunately, it proved much harder than I anticipated. Basically, my steps were
1. sew material,
2. stuff
3. throw away
4. repeat
I wanted to make the arms and legs more circular like the movie character and the Kenner Toy. But alas.. no could do. The frustration and dwindling amount of time resulted in my foregoing of the documentation.
It's fine! This is really sweet! It reminds me of the Michelin Tire Guy.
Whaleman7 years ago
awesome! I love the video! Maybe I should be this next year.....
macdadyabc7 years ago
thats pretty funny. i wore that same ghost busters jumpsuit to high school yesterday, and all the girls liked it. then i got on the roof and started screaming" i saw a ghost, i swear i saw a ghost". it was hilarious
canida7 years ago
Nice costume, and sweet video! You need some footage of stomping over hotwheels cars, lego structures, and action figures. ;D
Honus7 years ago
One of my fave movies of all time! I was actually thinking about this costume today and how funny it would be to do.