Instructables
Picture of How To Make A Giant Sandwich
Hey everyone. Here you will learn how to make a giant sandwich costume. I know not everyone needs one, but I like to think people most want one. I built this for the awesome guys over at Naked Castle. As always we invite viewers to improve our design and send up video clips of your projects. All you have to do is upload, and you could be featured in our monthly user submitted podcast.

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Here's the complete video:


Shopping List

1. Two big pieces of cardboard. (These will act as the large surfaces of our bread. If you can't find a big enough piece you can tape smaller pieces together.)

2. A bunch of 1-1/2 inch thick foam. (I used about 3 sheets, with each one being about 3 feet by 8 feet.)

3. A big can of Foam and Fabric Adhesive Spray. (You might even need two.)

4. Spray Paint ( Cream, Black, Brown, Green, Yellow, Red) (A certain giant evil retail store, let's call it "Tal-Mart" sells all the basic colors for .99 cents. Good feeling in your soul sold separately.)

5. Gaffers Tape

6. Black Handerchief

7. 16 Wooden Paint Stir Sticks (I grabbed these when I was buying the Spray Paint and they gave them to me for FREE!)
 
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Step 1: Building the bread

Picture of Building the bread
Keep in mind that you're going to have to do everything in this section twice. First thing you need to do is lay out a piece of cardboard and draw on your giant slice of bread. Make sure it's the size and shape you want. After you start cutting there is no turning back.

Step 2: Checking the size

Picture of Checking the size
Make sure you check the size of the cardboard. A sandwich too small or too big is not good.

Step 3: The crust

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Now we can add our crust. Take some of our 1-1/2 inch thick foam sheet and cut long strips that are about 5 inches tall. You'll need an electric turkey carver to really get this job done right. Then using some spray glue attach our foam crust to the outer edge of the cardboard. Spray adhesive is a contact glue, so you'll have to spray both the cardboard and the foam. Let it dry enough to get tacky, then stick it together.

Step 4: Reinforcing the bread

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Next we're going to re-enforce the flimsy cardboard with some wooden paint stir sticks. The reason I used these is because they are fairly strong, light and most importantly FREE! I taped the sticks down across the inside of the bread.

Step 5: The Fixings

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This is the part where you can get really creative. My sandwich ended up being a roast beef looking meat, lettuce and American cheese, but your sandwich can be whatever you want. It's time to take all those years of making edible sandwiches and apply it to a giant person suit. Lay out some more strips of your foam on the edge of the bread. Mark off the places you'll need to cut so that your foam lettuce, meat etc. fits right. Then start cutting! I really just started stacking everything on top of each other until it look right.

Step 6: More stuff

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Once you have the general shape, take some extra time to carve out some details. Little grooves along the edges of the lettuce made it look really cool. Now paint! Some one told me I had to use floral spray paint on foam, but regular spray paint works fine and is much cheaper!

Step 7: The face (optional)

Picture of The face (optional)
The guys over at Naked Castle wanted there sandwich person to be angry, but your sandwich can be happy, sad or even faceless. The angry face was a good way to hide a secret opening for the person inside to see out of. The secret is a black Handerchief. When glued in place on the front of the sandwich it just looks black, but from inside you can see right out. Like looking through a screen. The rest of the face is just poster board I stapled to the front!

Step 8: Putting it all together

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It's time to start gluing the heck out of this thing. This step is fairly easy and by far the most fun. Using generous amounts of our spray glue start at the bottom bread and work your way up. Glue each layer on top of the next. It's like making a real sandwich, but instead of mustard or mayo you're using toxic glue. Did I mention you should be wearing a paper mask when using glue and paint? Use a decent mask when applying large amounts of glue or paint, even if your outisde.

Remember, someone is actually going to wear this monstrosity. Stick together 3 long pieces of gaffers tape and you've made some pretty strong cloth straps. Once the sandwich is put together, crawl inside and tape each end of your straps to either side of the bread. When your done you should have 2 shoulder straps that keep the sandwich in place.

Congratulations, you're now the proud owner of a ridiculous costume. Please post your questions or comments.
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ALogan973 years ago
So now that we can make a giant foam sandwich, the next step is making one we can actually eat!

...Or sleep in! My god, this could be a bed if you'd fill it up with foam! Or a sleeping bag!

:D

poofrabbit11 months ago
This is great, I hope some more people see this instructable and make this! It would be perfect for the new Cloudy with a Chance of Meatballs 2!
hrodriguez72 years ago
i can get free cardboard at a COSCO WHOLESALE
Now the question is how do you eat a giant sandwich?
 Where do you  get the foam
hippyland24 years ago
or remove all of the every thing else besides the bread and spary a little collor on and you got toast
craftygreen5 years ago
wow I am impressed! this is awesome, the fact that you would do this is super creative and spectacular!
bobhill1255 years ago
i made one with out a face and my cousin bit it
codongolev6 years ago
can the sandwich play basketball? (referring th the above picture)
yeah! really, what's with the basketball?
possibly for size comparison.
how did you cover up that tape-seam-thing?
jongscx6 years ago
how hot does it get inside the costume?
there's a hole on the bottom.
---First - I LOVE IT! Funny creative people RULE!!! Now, for some questions: 1) Does this come with fries? Or chips at least? 2) how about a floatable version for pulling behind a boat? I can NOT waterski; tried; failed; repeated. But I'm certain a sandwich would never spit ME out! The kids would love riding in it and I've seen way stranger things (my friend pulls around a shrek's-head type device with like 10 kids inside and it's clearly fun for kids and hilarity for the onlookers and parents) 3) Perfect April Fools day gag for the family - replace all the beds in the house with XL sized bed sandwich, which is what I thought it was when I clicked the link. Thanks for being bold, funny, creative, and sharing this!
SMTHN FUNNY6 years ago
THAT WAS AWESOME!!!!!!!
LaxLovaLV7 years ago
You could make a cool bed if you mad the bread a mattress and made it a bit bigger. The bedding on the bed would look a bit weird if there was any patter what so ever on it but if you had white bedding you could make a pretty nice bed! I don't know, just a thought. You would have to change it a lot though. Coolio idea though! :-) {laura}
That just gave me a REALLY good idea. A sandwich futon!
this is awesome! i like sandwiches!
tomonto7 years ago
Jun 7, 2007. 1:40 PMTheCheese9921says:
Totally friggin rad, I was guna go as a ninja this Halloween, this is sooo better

you are inside my mind...i was gonna be a ninja till i seed this!!!!EVIL SANDWICH ARMY!!!!
umm, actually it says you posted june 8..... at 5:40....
its a quote and what would it matter anyway
oooohhhhh I misread sorry. I thought for some reason you decided to put a timestamp on when you posted.
it would be fun to make but my wife would say i was being a ham...
hahaha.
Amazing... Just amazing. ;)
Man, that's one cool looking sandwich.
csquatdbeat6 years ago
Hey I was wondering how exactly your able to see out of it? You said something about a bandana but could you clarify just a little bit more? Im probably going to make this bad boy for halloween.
MisterShot7 years ago
ok!now what??its really nice but whats the point?i agree with LaxLovaLV!if it was a bed it would be better!
gmm4life7 years ago
I didn't know you guys had an instructables account too!!
xaworld7 years ago
and what if i want to do an open face sandwich??? hahaha
Honus7 years ago
Awesome! That is a killer sandwich costume.
ania7 years ago
this foam is difficult to find! is it high-density upholstery type stuff? where'd you get it?
AlexanderDW7 years ago
Peanutbutt'a jelly time! *<:oD
runbread7 years ago
i made a giant foam shark costume using similar steps two years ago. nice instructable!
lame. Its a commercial from a group of theater prop hands going solo. Bay Area (snicker)
this is the most beautiful thing i have ever seen.
CameronSS7 years ago
That is amazingly cool. I was kind of disappointed, though--I thought by the title it was edible.
hg341 CameronSS7 years ago
me too!!!11!!!!!111
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