I have had many requests on how to make this costume. So, I'm going to attempt to walk you through the process. I'm sure you might be able to find easier ways to create it, but this is how I did this one. I hope this helps you! Sorry for not documenting this project with more photos. Should have enough for you to have a good understanding. If you have questions, please post them and I'll try my best to answer. Thanks!

This costume took me around 40-50 hours and roughly $100 to make.

What you will need:

-2 Yellow & 4 White Poster boards
-Acrylic Paint (Blue, Light Blue, Black, Yellow, and White)
-Masking Tape
-1 Blue Long Sleeve Shirt
-Lots of Gorilla Glue (2 - 18oz bottles)
-Paint Brushes
-Small Hand Saw
-Sand Paper
-1 Painters stick

Step 1: Design / Scale

The First step I took was to try and scale an actual Lego. Here are some pics showing a poor but effective way to scale the costume. As you can see, both pics don't match in height... but again this gives you a good enough idea of scale. 

On the first pic, you can see two rows of numbers. The first row, is pixels in the photo. Each pixel equals 1.5 inches. In the second photo, each pixel equals 1.2

Absolutely the BEST lego costume on the web! My 8 year old son is in AWE. Too late for this year, but definitely next year!!! Also, what about using a pool noodle for the bendy part of the legs?
I grew up playing with legos (who didn't??), and I am 99% sure that my head just exploded from the sheer excellence of this project. Good job sir, you are now the proud owner of 10 internets.
Coolest costume ever!
people!!! need help! so, two questions, i've got one day to buy, and build this costume. Firstly, whats a good replacement for styrofoam for the curves, because i can't seem to get hold of any in the UK. Also, is it possible to build in a day? I'll paint it the next day?? <br>Please answer quick!
Styro foam from B&amp;Q its a building material
plz reply
this is one of the best indestructibles on lego man i have seen! looks good and is explained pretty good..thank you!
This has got to be the best looking Lego minifigure costume I have ever seen very good job sir!
The best instructions ever!!<br>
Okay, well sorry about the triple vision! First I could not get it to post, now it is way overboard.
Here is the Lego batman costume that you ask that I post if I went ahead and made it. I had to chop off the bottom of the legs even though I hinged them because he could not walk up steps very easy. I was wondering if the thin foam I covered the thin cardboard mask in came in really large sheets or rolls? That would have made making the legs a lot easier. I was going to put his hands through the lego hands, but that would have had it too difficult to grap the candy bag so I glued and guerilla-taped them to the top of black gloves instead. Thanks for the styrofoam idea though for the hands. It does sound horrible being cut and does make a mess for sure ☺.
what could you use instead of a screen to see through it
Speaker fabric would probably work.
OK thanks
maybe panty hose would work too?
mine is nowhere near as pretty took about 10 hours and 30 bucks so far (im still painting) and if i could find my cable i would upload pics great ible i love it<br>
I ended up using your instructable as a rough idea to make mine, ended up using the foam core for the top and bottom of the head and neck. One Suggestion i have is to leave the top part open like an older lego and cut out a small hole to put in a computer fan like I did. Thanks for the instructable, won first place at a costume contest from the one I made in 3 days.
What are the dimensions for the circle pieces that make up the head?
This is stinkin' amazing!!! My 10 year old daughter will love this! I may even have to make one for our company Halloween costume parade. Thanks for the tutorial.
Thank you so much! Was not expecting to see this. My son told me several days ago that he wanted to be Lego Batman and I have been raking my brain for ideas. Last year he was Edward Scissorhands and I thought that costume was a pain in the a##-took many hours and also trial and error. This will be even more challenging I think.
If you make it, please post some pics!
This is so much more legit than the legoman costume I made last year us it very hot? The one I made was only the helmet and hands but I was burning up when I foolishly wore it to the club :P
thanks! Yeah, this got very hot... Had to take off the head often.
How big should the sizes have been for the styrofoam
what about putting a helmet on the inside of the head so that it could swivel and turn?<br>
Woah, awesome costume! This'll be sure to drop a ton of bricks!
<big><strong>KITEMAN WANT!</strong></big>
Epic! I love it.
Can you include where you bought your Styrofoam?
Yeah, I just went to Menards. I think each pack was around $10.
Thanks for your reply, but I don't have one of those in Tuscaloosa, AL. You think Micheal's or Lowes or Home Depot would be worth looking into for that kind of a thing? Also(hopefully not being a pest, but..), if they don't have the exact size you got, what should I aim for?<br>
Menards is very similar to Home Depot or Lowes. I would try there.<br>
Thank you!<br>
Just a few color changes and you can have your favorite Lego Harry Potter/ Indiana Jones/ you get it right? character you want. Thanks for the DIY, Legos remind me of all the childish fun I still have.
Best costume EVER!
Okay, I've added a few more details (how the head stays on, how I made the feet) and added a few more pics. Thanks again for looking! If you have more questions, please ask. <br><br>Also, I'm almost finished with my costume for this year. Once complete, I'll be uploading a tutorial for it. I'm very excited about this one!
I'm kinda confused about the legs and feet...
Thanks for mentioning that... I guess I kinda skipped that. I just took some more pics, and ill update the tutorial soon here. Thanks again!
so cool. can you see well in that suit?
Yeah, it has a much better viewing area than the one pic shows.
dude, this just made my night LOL awesome!
pretty awesome !

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