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)
-1 Blue Long Sleeve Shirt
-Lots of Gorilla Glue (2 - 18oz bottles)
-Small Hand Saw
-1 Painters stick
Step 1: Design / 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
Step 2: Shaping Styrofoam
Step 3: Building the Body
Step 4: Finishing the Head
The head is removable. This was very important due to how hot you get wearing this thing. The head stays attached to the body with 3 pieces of wood (a paint stir stick cut into 3 pieces). I just cut 3 holes into the styrofoam neck, filled them with glue, and stuck the sticks in there until they dried. I also cut 3 holes into the top of the body for the sticks to rest in. This makes the head not turn, and gives enough support to stay on when walking / dancing. See photo 4 for a visual.
Step 5: The hands and feet
The Feet - I cut out of styrofoam, 4 L shapes (2 per foot, 1 for each side). I then just glued smaller pieces of styrofoam to shape each foot. Once the glue dried, I covered them with cardboard and poster board. Then applied some black paint. The one issue I came across was trying to figure out a way for my feet to go in and out of these with ease. I also need these fake feet to move as I walk. So what I did was, I put my foot in the fake foot and figured out where the top of my foot was and glued some more styrofoam to surround my foot. I really feel there may be a better way to do this.
Upper Leg - As you can see, there is a small bump that represent the upper part of the Lego mans legs. I used some styrofoam, covered with poster board for the right, left and back. And used cardboard covered with poster board for the curved front. I then glued this to the body. Sorry I don't have a good pic of this part. The last photo circles what I'm talking about.