Introduction: LEGO Man Costume!

Picture of LEGO Man Costume!

Playing with LEGO's is past time for many and I decided to make my very own life-size mini-figurine costume for Halloween. When I planned this costume, I was making two for myself and a buddy so I started working on this costume three months in advance to have ample time to create this. But lucky for you I will be describing the process so you could make it over a weekend.

Step 1: Materials!

Picture of Materials!

Tools needed:
-X-acto Knife
-Steak Knife
-Measuring Tape

-2" and 8" round containers/bowls (for eyes, mouth and hole for head)
-Large boxes
-12" Cement form tube (found near construction materials)
-3/4" Styrofoam Insulation(found near fiberglass insulation) *
-2-3 cans of Yellow spray paint * (Krylon's Sun Yellow is a very close match to LEGO yellow)
-2-3 cans of red/blue/green/other spray paint (color of body, your choice)
-Sandpaper (400ish grit)
-A sheet of copy paper
-High-density foam
-Spray glue (preferred over hot glue because of styrofoam)
-Packing tape
-Gorilla glue
-Speaker fabric or black panty hose (So you see out of but others cannot see in)
-A strip of Velcro (the hook side)
-Yellow Kitchen gloves
-Long sleeve shirt (matching to body color)

*Here's the deal about spray paint and styrofoam. Spray paint cans contain an aerosol that loves styrofoam and dissolves it on contact. I will explain how I overcame this and improve the durability of the head in a later step.

Step 2: The Head!

Picture of The Head!

This is the signature piece of the entire outfit and will take the longest to create but take your time; your patience will be rewarded. I apologize in advance that I did not document this as well as I should have. I will detail everything to the best of my ability. Don't hesitate to ask questions if I could explain a part in more detail.

First you will need to measure from the top of your head to your chin and round up to the nearest inch. My noggin is about 8.5", so I made it an even 9". This will give you how much you will cut from the form tube. Measure that length on the form tube and starting cutting with the handsaw carefully to get the straightest line possible, I used a rubber band to aid me. After its separated, sand the edge you just cut to smooth it down.

Next your going to cut some styrofoam, this can get very messy so have a vacuum/shop-vac on hand. Take the form tube you have cut off and draw the circle out on the styrofoam. Take two sheets of the styrofoam and cut the circle out slightly bigger to sand down later. Do this one more time to create both the top and bottom of the head. You'll have four 3/4" disks total to work with. Two disks for the top and two for the bottom.

The trickiest part of making the head is making the curved ends. Use the spray glue to combine two disks together. Your going to sand this curve into the styrofoam, so take your time and check your work to make sure the curve is even throughout the disk. This will take awhile and there may be easier ways to do this; there could be a part or product somewhere that fits the form tube and provides the curve needed. I just worked with what I had and it turned out great.

Once the curves are similar to the mini-fig's curve, we need to attach the ends to the form tube. Remember when I told you how spray paint loves styrofoam? Well this is the step that you have been waiting for. We are going to tape over the ends.*See alternative methods below* The main reason is to provide that barrier so the styrofoam doesn't make like a magician and disappear. The tape also secures the foam and makes the head a much more durable. Decide which side you want to be the top and secure it by using one continuous strip of tape across the styrofoam, leaving about an inch on the form tube. Continue this until none of the styrofoam is exposed anymore.

Before we tape up the side your going to squeeze your head through, we're going to need a hole made. Take the 8" bowl you'll use for the face later and center it on the bottom piece of styrofoam then mark its position. Now cut the piece out until you have a styrofoam ring. Don't discard this disk, we'll use it in a bit. To tape the bottom is slightly different. Instead of taping across the gap, wrap it around so attaches to the inside of the head. Do this until none of the styrofoam is exposed.

The stub on the top on the head is made up of three 6" disks from the styrofoam. Lucky for you, the 8" disk you just cut out is already two pieces of foam. Cut the disk down to a 6" diameter, make another 6" disk from the foam and glue to the others and you have the stub. Sand the edges so they are smooth.

Now its time to ventilate your head before you attach the stub. Find the center on the top of your head and use the 2" cup to trace your vent hole. Cut through the tape with the X-acto knife and the styrofoam with the steak knife. Find the center of the stub and do the same. Tape up the stub until no styrofoam is showing, leaving the vent hole uncovered. Use 4 or 5 dabs of the Gorilla glue to attach the stub to the head, aligning the vent holes.

After a few suggestions, I figured it would be a good idea to include them into this instructable. Destructions presented a couple of ideas where you could use a higher density Styrofoam then use a lightweight spackel to fill the gaps for an even finish. Yoyocrazyguy mentioned paper mache, which would solve just about all the issues with Styrofoam as well as keeping things nice and smooth. Teethdoc used a product called DecoArt MagiKote which is made specifically for Styrofoam to harden it into a smooth, paintable surface.

In my opinion, the Magikote would work the best in this application. All you would have to do is brush on a couple of coats of it onto the Styrofoam areas to be painted, let dry overnight, then sand till smooth. One catch is that you would have to make sure the Stryofoam is secured from the inside of the head with either tape, gorilla glue, or a combination of the two.

Step 3: The Face!

Picture of The Face!

Alright this takes a bit of ingenuity but I'll walk you through it. The picture you see is the actual dimensions of the LEGO mini-figurine. No questions on how I obtained it, I just did what was necessary. Now the scale of the mini-figurine is about 1/32. That means the the numbers you see need to be multiplied by 32 to get life-size scale. Of course, this can always be adjusted for kids or babies... LEGO babies might be just bricks.

This part is a little hard to explain so I have pictures to detail the processes as well. I have estimated the eyes are about 2" in diameter. So take that 2" round object and sketch it onto the copy paper. In the LEGO man diagram, the eyes are the same distance apart (end to end) as the stub on top of the head, about 6". Mark the distance but don't draw the other circle yet. Take the paper and fold it so the line you marked matches with the other eye and sketch the circle on this side. Unfold it and you should be able to see the mark you made on the other side, redraw that circle on the other side. This is to make sure the eyes are level with each other, we don't want to make a lazy eye LEGO man.

The smile is simple but difficult to recreate. The "peaks" of the smile is 2" from the bottom of each eye, mark each point. I found that a 8" round bowl creates the right radius of the smile. Align the bowl with each mark and connect the dots. Now mark two more points one more inch below each peak and connect the dots once again with the bowl. Rounding the ends of the smile was done by free hand, do your best to replicate the ends and use a pencil so you can perfect it before you begin the surgery. Mr. frob has suggested using a compass for the ends. A 1/2" radius circle will give you the right curve to connect the end points of the smile.

Step 4: Positioning the Face.

Picture of Positioning the Face.

I've noticed that on the forming tubes there are ridges where cardboard meet together. Find a smooth side to work on for best results.

The bottom of the smile is located roughly 2.5" from the bottom, but the length of your head could alter the look, so do your best to center the face on the head. Now tape the copy paper to the face, making sure its level and prepare for surgery!

The way I took was use the X-acto knife to cut the eyes and smile out of the forming tube. This takes awhile and there may be other ways to do this if you have the right tools. Take your time, any mistake and you might have a LEGO man scar on your hands.Cut the face out slightly smaller than what is drawn, when you sand it later to smooth it out it will remove the extra cardboard.

Step 5: The Body!

Picture of The Body!

I did not plan as well for the body as I did for the head, but it did turn out pretty nice. First you will need to measure your shoulder's length and your waist depth (from the chest or stomach, which ever is larger.) You'll need to add a few inches to the sides so you can breath and move around easier. Last measure the length from your shoulders to your waist. 

Once you have the numbers down you can grab the boxes and start making the body. The LEGO mini-fig as a wider waist than its shoulders and looks much like a trapezoid. So when you cut the front and back of your body pieces, make sure you angle the sides similar to that of the LEGO mini-fig. The final dimensions of my LEGO body was 15" for the shoulders/top, 23" for the waist/bottom, 21" from top to bottom and 13" deep.

Now that all the body pieces are made, we can tape up the parts to make the whole. Once the body is taped together, we'll need to make holes for your head and arms. Cut the top big enough to fit your head trough comfortably. The arms holes need to be much larger than the arms themselves to allow full movement in the costume. Cut a 'U' shape on the sides to match up with the top piece of the body. Apply more tape when necessary.

Step 6: Painting!

Time to paint! Rough up the all the outside tape on the head and body a bit with the sandpaper so the paint adheres better. Use light coats of spray paint to stop build up. Once the first coat is finished, let each piece rest 8hrs or over night. Before adding the second coat, lightly sand the entire surface to get rid of any bugs or dust that may have stuck to it. Apply the second coat and let it rest again. Continue this until the cardboard doesn't show and the paint is even throughout. I think I did three coats on the body and four coats on the head.

Step 7: The Brains!

Picture of The Brains!

Okay, LEGO men didn't have one, but the step is for the inside of the head, i.e. where the brains are.

Get the hook side of the velcro and stick it around the holes of your face. This will provide the "glue" for the speaker mesh/fabric that you will look through. Cut the speaker mesh to fit over all the holes and push it against the velcro until it stays. 

The foam is to secure your head inside the LEGO head. Cut the foam and place it in strategic spots so when you turn your head, the LEGO head stays in place. Use the Gorilla glue to apply foam where you need it and let the glue set over night and apply more where needed.

Step 8: Be One With the LEGO.

Picture of Be One With the LEGO.

Alright, you have the head and the body made. Don your jeans, long sleeve shirt and kitchen gloves and prepare yourself for the night ahead. Being here in Florida, October can either have cold or warm weather. You might want to forgo the gloves if it becomes too hot for you as you will be sweating a lot while walking around. Lucky for you, you have a vent on your head to allow some of the heat escape. You could even put a small computer fan in the hole to improve cooling.

Of course this is not the end of your LEGO costume. There are hundreds of LEGO characters you can create. I plan to redesign my costume to look like a pirate for Gasparilla at some point. Perhaps you're going to a pimps and hoes party. Grab a cane, make a hat and paint a suit on your LEGO costume and stride in style. Have fun with it and be creative!


T0BY (author)2016-12-07

This is amazing!

kumarkiran (author)2015-11-22

So nice..great ideas...

ART2D made it! (author)2015-11-02


AAVin made it! (author)2015-11-01

Hello !! Thanks so much for these awesome instructions. My husband and I made bride and groom Lego men and took first place !!! We were pretty happy with how they turned out ! We used styrofoam for the top of the head and a pool noodle for the bottom (saved us a lil bit of time bc we were under a time crunch ) Worked out perfect !

LangdonHarris (author)2015-10-30

I am going to try and be this for halloween. I'm gonna have to pull an all-nighter. Great instructions! Thanks!

CatharineL made it! (author)2015-10-27

I didn't do the rounded edges for the heads -- I used dollar store tin pie pans and hot glued them onto the cement form tubes (both the pie tins and the forms are 8" diameter). The bodies are one box inside and then I tapered outer edges to the outside of the existing rectangle boxes with packing tape. I used a drill for the eye holes. Acrylic satin finish craft paint for the details and yellow construction paper that I traced a batman logo right on top of my computer screen (zoomed to the size I needed) and the cut it out and colored in the bat with a sharpie marker. Same for the belt -- yellow construction paper colored with sharpie and for emmet's belt black construction paper. All glued on with hot glue. The batman mask is cardboard box pieces cut and rounded aroun the form tube and the packing tape all around it. The black line work on emmet was hand drawn with a sharpie and the help of a large metal rule for the straight lines, penciled on and then traced over with the sharpie. The kids are very excited for Halloween this year. Thanks for the great tips. Was a huge help, especially the foam inside the heads so they can stay on and not be wobbly!

TomN2 made it! (author)2014-11-02

HI there, i want to thank you VERY much for the instructions that you put on here.. they were exactly what i needed to put my costume together. I went the Ninjago route as its my son's favorite. I pulled off a Sensei Wu costume.. Your instructions for the head were fantastic! What do you think?

The Night Flower (author)TomN22015-10-13

Wow. That looks awesome!

bobaki (author)TomN22015-02-04

how did you make tha hands and beard ?

rich.pea made it! (author)2014-12-15

Hi guys, here's my Lego Spaceman costume I completed last weekend for a Space theme Fancy Dress party. Any construction questions, ask away!

Wow. That looks awesome!

kdc123abc (author)2015-10-05

These are AWESOME!!! I'd be willing to buy a couples Lego costume if anyone is looking to sell theirs?! Had the idea of Emmett and Kragle but I love these! Please let me know!

RoxanneE (author)2014-10-02

Amazing costume! I'm working on a Lego Movie Wyldstyle Halloween Costume. I've been following your instructions. Any ideas on how to create the hair? I would greatly appreciate it! Thanks.

Kaged Kombat (author)RoxanneE2014-10-05

Thank you! The hair would be tricky but I have an idea. The foam you use inside the head can be re-purposed for the hair. It would take some time to trim to shape but you can use a combination of wire to push the foam together and glue to hold it. Shape it to the Lego head so it can slip around it like the normal mini figs do.

Painting it is another matter. I think the best way to do it is use either Plasti-dip or Flex-seal. Both are rubberized spray-on cans you can apply to various objects. A few coats of this should cover up the foam's cells enough to leave a smooth finish so you can paint the blue and pink streaks in the hair.

You'll want to keep it lightweight but strong enough for the occasional run in with a wall or person. Also keep the top breathable by cutting a hole in it and lining the top of it with some spare speaker fabric.

You have plenty of time to work on it, so take your time. Best of Luck!

RoxanneE (author)Kaged Kombat2014-12-13

I forgot to post my end results. Thanks so much for the instructions! They helped a lot. Our costumes were a hit!

FitMotoChick (author)RoxanneE2015-08-31

How did you do the hair on yours??

RoxanneE (author)Kaged Kombat2014-10-06

Great tips! I'll have to look for the foam. Haven't purchased it yet. Thanks!

tammy.cobener (author)RoxanneE2014-10-16

I used vinyl material and fabric stiffeners for the hair.

JaneJ1 (author)RoxanneE2014-10-09

I'm thinking about using art wire mesh to form a template, and then covering it with plaster cloth. We'll see - good luck!

RoxanneE (author)JaneJ12014-10-10

Good idea! I read a blog where someone created a cosplay wig in a similar way.

lcrookston made it! (author)2014-11-13

Thanks for the instructable! I used it to make the head for my boyfriend, and he made his shirt piece, he was Benny the Spaceman from the movie, and I was the angry Unikitty!

For my head, I nested four pieces of the concrete form, three for the helmet, and one for the face. I covered my foam with wood filler, and a last layer of wood glue before painting, it worked great! Although, this design doesn't have a vent on top, so it might get toasty.

lcrookston (author)lcrookston2014-11-13

I couldn't help it, here are some in-process shots of the boyfriend's helmet / head:

darkmatter762 made it! (author)2014-10-28

I gathered some more photos of my construction. We did a few things differently, and I may actually write my own instructable to show more details. But your instructions were vital to the success of my own project, so thank you!

We didn't use tape to secure the foam to the forming tube, we used paper-mache on the inside, strips of newspaper soaked in glue which worked pretty well to secure them. We also used a lot of spackle to smooth everything as best we could. We painted with an acrylic base coat before using the spray paint.

I was SO lucky in that I found two concrete forming tubes, one inside the other, which meant that the larger one could become my space helmet. So definitely check out those forming tubes as they are not all the same as one may think!

I decided not to do the body, or try to make legs, as I wanted to be able to move, sit, dance etc as much as possible. So just found lots of blue clothes.

The hands were made using Thomas Willeford's fleather material: two sheets of craft foam stuck together with double-sided duct tape. A thick bendable wire was sandwiched in-between those foam sheets to allow the "claws" to be bent into the right shape. I attached the claws to two simple fleather bracers (held together with velcro) using 4 snaps. This allowed me to take my hands off when needed.

I used two overlapping pieces of hosiery for the mouth, so I could poke a straw through and still have a beer :)

lcrookston (author)darkmatter7622014-11-13

Nice! I also made the space man head for my boyfriend! I wanted to do a removable helmet, but was afraid time would not permit, so I nested three pieces of concrete form by cutting a vertical section out of the inner two to make the helmet, then i inserted a fourth to serve as the face. I love all of your details like the jetpack and hands, and the mouth hole for drinking!

jaymbartfast made it! (author)2014-11-03

My shoulders are too broad to taper the box that I had, but I manager to still win the work costume contest. Thanks for the instructable. I couldn't have figured out the head without it.

alightfoot1 (author)2014-11-02

We tried something similar for this year.

mattchogan made it! (author)2014-10-30

sweet instructable! I spent probably three plus full hours on making the head. I made it out of a bucket and just used styrofoam for the bottom curve. Bucket is cheap, light and pretty decent working material. Hard to cut details though. The plastic cracked a bit when i tried to cut it and my eyes aren't perfectly round but oh well! I just sanded it quickly and the spray paint stuck great! Two coats and you couldn't see through to the original color. I covered the bottom foam with duct tape and scratched that up with the sand paper before painting it. Painted didn't adhere quite as well. There's also a bit of gorilla glue holding the bottom to the bucket and also the nub (hidden in picture) to the top.

For the body i just did one angle piece of cardboard in front, hung from my neck from a big stretchy rubber band i had. A string would work fine too, probably. Other than that, lots of tin foil, cardboard, duct tape and spray paint plus some time making a cardboard stencil. I spent a lot of time on decorating the body. Lots of drawing, cutting, spraying, sticking tin foil, etc. and you gotta make sure to do it all in the right order. Crown is from cardboard and tinfoil. Dishwashing gloves and a shirt to match the spray color makes you a Lego King! Sword to come tomorrow! Probz just more cardboard tinfoil and tape for that...

Extra materials i used,


Tin foil

Rubber band


A long and fun process, best accompanied by red wine, cheap beer and a grilled cheese with soup. Also it's helpful if you have other people around to shoot ideas off and to generally sooth your soul when your frustrated. Mega props if they also cook delicious homemade soup.

kathy.busby2 (author)2014-10-30

Won 1st Prize at the church costume party! Thanks for the idea!

IsraelH1 (author)2014-10-28

Any advice on how to put the body together? Did you simply tape the sides?

darkmatter762 (author)2014-10-26

Thank you for this great instructable! I just finished my 80s Lego Spaceman based on this tutorial!!! Here's a photo on Instagram:

Love this! My boyfriend really wanted to be the spaceman. I'll have to show him for next year. Wow!

Far out man!

Legomyeggos made it! (author)2014-10-26

Thank you for the directions! It took longer than we thought but was well worth it and everyone loved it!

Helpful Note: We actually used a foam we purchased at Home Depot (the purple stuff in the photo) thats paintable which made things easier so that we didn't have to tape the whole thing or prime it. We bought 4 of them to have enough for all the parts. My boyfriend made my eyelashes and lips out of construction paper and I just glued it on. I would have loved to do hair but ran out of time. We also won at the costume party, one party down and one more to go. Thanks again!

Kaged Kombat (author)Legomyeggos2014-10-27

Great to hear there's another type of foam out there with paint-able properties. I might have to add it to the instructable for others to look out for. Thanks for the suggestion!

Legomyeggos (author)Kaged Kombat2014-10-28

I found the link! I think its a few $ more than the other insulation or maybe the same. You need 4 pieces of it for everything.

fontofontaine made it! (author)2014-10-26

Thanks for the brilliant instructions on this one. Made it on Saturday over the course of the day and wore it out that night. Still didn't get to smooth it out as much as I'd have liked, body shape is square rather than angled, but I think it turned out well anyway.

You did a great job in such a short amount of time! What's really great about the Lego Mini Figuring is that they are so recognizable. Even if you're strapped for time, you can pull something off that everyone can relate too.

felipeseiber (author)2014-08-31

Made one as Emmet and Lord Business from the Lego Movie with a friend for Dragon Con this year. We were such a hit we had a line of people wanting to take pictures with us.

This is a great Instructable. We ended up priming the whole head with some standard wall primer to solve the spray paint Styrofoam issue then sanded it to try and smooth it. Added a 6 inch computer fan to the top of the heads and a 9v battery to keep us cool through the day. If you add a fan make sure it blows out as we found that kept us the coolest.

tempo68 (author)felipeseiber2014-10-26

What did you use to make the hair for Lord Business? Do you have pictures of the back of his head?

felipeseiber (author)tempo682014-10-27

His hair was also made of Styrofoam. This one I don't really have any pictures of as it was the second one I did. I also unfortunately no longer have it as my friend took it home with him. It was a bit tricky, so I will do the best I can to explain. I've also attached a diagram. You have to first cut the bottom of his hair. It's the shape of a partial octagon. What I did was cut the octagon shape then put the tube over the foam to cut the arch on the inside. Glue this to base to the outside of the head first. Then glue the sides onto the base. Found it easiest to tape the sides of all the sides together then glue to the base using the tape as a sort of hinge. Using the tape as a backing you can further glue the vertical seems for a stronger hold and to smooth them out. Glue on the top and then 2 layers of styrofoam for the mohawk part. Then glue on the front side burns and mohawk forehead part. Once it all dries drill a hole on the top for the fan. Did the same in using wall primer to cover everything before spray painting.

Hope this helps. I'll have to make sure to take more pictures and setup a second instructable next time :)

tempo68 (author)felipeseiber2014-10-27

Awesome. Thanks for the picture and the diagram. Appreciated.

felipeseiber (author)tempo682014-10-27

Was able to locate 1 photo of it all glued and drying. The painters tape was used to apply pressure while it was drying since it didn't rip up the styrofoam when you took it off.

starr111 (author)felipeseiber2014-09-27

What did you use for Emmit's construction hat? Or did you buy it?

felipeseiber (author)starr1112014-10-09

I actually made it out of Styrofoam. I unfortunately did not take as many pictures of this part as I should have but I've attached the one that I do have.

I used a styrofoam wreath and half dome glued together. Then cut thin arches out of some of the scrap styrofoam board left from making the bottom part of the head. Glued those onto the dome to create the ridges. Then used sand paper to roughly round the styrofoam ridges. Next I used spackling to finish smoothing out the ridges. Then glue to the top of the concrete tube. Once it was all dry I used the standard wall primer to coat the styrofoam before sanding and spray painting the final color.

Wreath: (make sure the diameter matches the concrete tube)
Half Dome: (not exactly what I used, couldn't find it online. I found a standard white styrofoam dome the exact same diameter as the wreath at my local store)

starr111 (author)felipeseiber2014-10-10

thank you for that. I found a 2 gallon bowl that is about right, and am going to glue down some roping for the ridges. Wont be as good as yours, but not sure I have the time for more styrofoam sanding ...

thank you for the reply

starr111 (author)starr1112014-10-27

OK so here is how mine turned out. Thought I had the styrofoam well sanded but came out a bit rough in the end (I also uses foam wreath rings so I didnt have to cut that much, maybe that was it). Helmet I found a plastic planter that was ... well ... for me close enough!

Thanks to all!

Forgot to attach image

RoxanneE (author)starr1112014-10-02

I'm wondering the same thing.

I have yet to see the Lego Movie but it appears like I need to. Great expressions! I knew adding a fan would help, I'm glad it worked well for you!

katsupe (author)2012-11-04

Thanks so much for your creativity... it allowed me to appear to be creative... I made 1 and then my other 2 kids wanted them too... The girl hair comes off just like a real lego... and I used yellow beer koosies for the hands... They were a big hit!!!! Again... Nice instructions!!!! Great Job!!!!

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Bio: I'm just a guy that loves to make things. Art, electronics, crafts, woodwork etc. You name it, I've probably at least tried it ... More »
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