Instructables
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.
 
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Step 1: Materials!

Tools needed:
-Scissors
-Handsaw
-Pencil/Marker
-X-acto Knife
-Steak Knife
-Measuring Tape


Supplies:
-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)
-Jeans

*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.
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Hm...I just came up with a thought. Instead of using tape, how about paper mache? I think that would be easier to paint and come out with a smoother look.

Using paper machete is a fantastic idea, for all or part of the head. It takes a while to dry, and if you are going to wear the costume, make sure you're not using water soluble glue, or your body sweat will break it down quickly and cause the paint to run. You can treat the paper machete costume afterwards, or use glue that is waterproof. Google waterproof paper machete. http://www.ultimatepapermache.com/waterproofing-papier-mache

Kaged Kombat (author)  yoyocrazyguy4 years ago
Good idea. Never thought about using paper mache. You could smooth out the entire head for an even finish.
pikminkal2 years ago
what do you think of using the egg crate foamy material for inside the head? i'm getting materials together this week for my son's costume!
Kaged Kombat (author)  pikminkal2 years ago
Egg crate foam would be a great replacement to the foam I used. Would help with ventilation too!

Also, I've used the top of a 2-Liter soda bottle to hold large "helmet" masks like this one off the top of my head, without making it sit on my head causing sweaty hair. I simply take whatever is up top and glued in the top screw cap, then take the top of the bottle and slice several strips that fan out and sat on top of my head. Best ventilation I could think of at the time.

hsmith342 years ago
All that carving of styrofoam to make it round seems pretty complicated. Why not just use pool noodles that you find at Dollartree? They are already rounded and pretreated with a water repellant coating so they shouldn't react to spray paint like regular styrofoam. Plus they are pretty cheap. One noodle should work for top and bottom.

Love the pool noodle idea for the curve.

Kaged Kombat (author)  hsmith342 years ago
I never thought of using those. Give it a shot, should be easy to do. The hard part would be keeping it in place on the helmet. Tape should take care of that though.
RoxanneE18 days ago

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.

I used vinyl material and fabric stiffeners for the hair.
JaneJ1 RoxanneE11 days ago

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 JaneJ110 days ago
Good idea! I read a blog where someone created a cosplay wig in a similar way.
Kaged Kombat (author)  RoxanneE15 days ago

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!

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

ccscull5 days ago

For hair I was thinking about using the expanding spray insulation foam.....it doesnt harden right away so if you do a little at a time (it expands a lot) you could use a brush or something to get it the way you want....then paint it.

MoisesE19 days ago

How much did it cost in total???

Kaged Kombat (author)  MoisesE19 days ago

It has been so long, I'm not quite sure. I think in total it was around $70, but I had all the tools I needed already. Now there is enough cement tubing and styrofoam to make about 3 or more outfits. So the cost could be cut dramatically if you split the cost among friends.

jseiber1 month ago
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.
temp_-1391413726.jpgtemp_1848654799.jpgtemp_111893624.jpg

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

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.

Directions:
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: http://www.michaels.com/styrofoam-floral-wreath-flat-white/10531079.html#q=styrofoam&start=21 (make sure the diameter matches the concrete tube)
Half Dome: http://www.michaels.com/floracraft-dry-foam-half-ball/10355246.html#q=half+ball&start=3 (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)

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

jseiber jseiber11 days ago

Forgot to attach image

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I'm wondering the same thing.

Kaged Kombat (author)  jseiber1 month ago

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!

Rosejn11 days ago

Thank you so much for the directions. My son broke his leg first day of senior year and wasn't interested in dressing up for character day during spirit week. I changed his mind and he even added a little something extra!

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yangd15 days ago

How do you make the measurement "from the top of your head"? Is that from the top of the forehead, or the highest point on the front of your head? My head measured in the latter way is 9.5 inches, do I just have an enormous head? Haha

Kaged Kombat (author)  yangd15 days ago
That's from the highest spot of your cranium. You want to make sure your head fits inside that tube so when the top gets enclosed the Styrofoam sits comfortable on your head without needing to remove material.
katsupe1 year ago
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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Would you be interested in selling your Lego costumes?

Kaged Kombat (author)  katsupe1 year ago
They look fantastic! Thank you for the kind words, it makes me happy every time this instructable makes someones' night memorable!

Any chance you have a Lego costume for sale for a 6 year old. These are absolutely amazing.

Man, I would honestly pay you to make me a Mr. and Mrs. Lego head costume for Halloween. Any interest in making some money?

Thank you for the offer, but I don't think I'll have the time. When I was a student, I thought I could make a limited supply for this time of year. Once I got a job, all the extra time I had went away. There's a chance I might perfect the process and start making sets again in the future but I don't know when that will be.

XaqFixx made it!1 month ago

I made this a few years ago based on this 'ible. The following year I repainted the mask as a zombie minifig.

LegoBrains.jpgLegoZombie.jpgMiniFigCostume.jpg
Kaged Kombat (author)  XaqFixx1 month ago
That's great! I've been meaning to dust off my own and put a new twist on it.

definitely trying this on my next fancy dress party.

Thank you so much for this tutorial, I dont know how we could've made the costume without these instructions!
Lego Superheros.jpgDowntown.jpg
kbates8711 months ago
Thank you so much! We had an amazing Halloween!!
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Mrs_Tish11 months ago
Thanks for this! My 10 year old.is a huge Zelda fan, and we needed a creative twist since he went as Link last year. This was perfect for us. :)
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