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:
-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.
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jseiber19 days 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.
Kaged Kombat (author)  jseiber14 days 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!

XaqFixx made it!14 days ago

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

Kaged Kombat (author)  XaqFixx14 days 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
kbates8710 months ago
Thank you so much! We had an amazing Halloween!!
Mrs_Tish10 months ago
Thanks for this! My 10 year a huge Zelda fan, and we needed a creative twist since he went as Link last year. This was perfect for us. :)
Kaged Kombat (author)  Mrs_Tish10 months ago
LEGO Link! Awesome job on the shield and sword too!
fallen_petals11 months ago
Amazing idea Kaged Kombat! I've been looking for a costume to make to wear for Halloween, and for the costume contest at work, that wouldn't be very difficult to make, and I think this is the one. I just have a question, since the costume adds extra volume and bulk– is it difficult to get through doors?
Katsupe- I love the additions that you made to the costumes. How did you attach the hands(and can't you still grab and hold onto things)? Also, how did you make the hair and make it detachable? And, did you use a printout or paint on the Lego logo?

Lastly, does anyone know how to reduce the heat and increase visibility(would cutting eye and mouth holes work-I could wear a light mask so I can still see and others would see black into the holes)?

Again, wonderful job Kaged Kombat!
Kaged Kombat (author)  fallen_petals11 months ago
Doors never were an issue for me. You could walk sideways if you might think it is too wide for the opening. I mentioned about adding a fan for circulation. It does get hot in there if it's not that cold out. However, batteries only last so long and placement of a fan would be tricky but it's entirely doable. Good luck and have fun!
pshotton1 year ago
Thankyou so much for this, I made a couple of similar heads, using your instructions as a guide. The end results were very well received. Luckily I sourced some thicker styrofoam, so didn't have as much glueing to do. I used PVA glue to cover the styrofoam before painting and also used undercoats of Plasti Kote spray paint, which seemed less styrofoam averse. :) I'll try and post some pictures of the end result later on.
Geekaton1 year ago
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??
Please answer quick!
plz reply
Kaged Kombat (author)  Geekaton1 year ago
The painting will take the longest due to the dry time required between coats. If you have a heat lamp or enough sun light, you could speed it up. As for a replacement for the foam, I'm not sure if you have them there, but there are these foam noodles used while swimming that should work. Good luck!
Thanks! Also do you know of any other method instead of using the concrete form pipe?
Kaged Kombat (author)  Geekaton1 year ago
There is a plastic 5 gallon bucket that I know of that might do the job. You can find them at hardware stores. Looks like this:
Do you reckon I could do it in a day?
Hi, thanks again so much for your help! I am going to use polystyrene for the neck and head bit, and then a thin layer of cardborad in-between, like this one:

Does that sound good?
Kaged Kombat (author)  Geekaton1 year ago
No problem. The paint dries naturally to a gloss finish. That looks good to me, best of luck getting it done in time.
Also, how did you get ur paint so shinny?
Geekaton1 year ago
And do you reckon i could do it (except the paint) in a day?
ocodinero1 year ago
buenos dias espero aprender mucho en esta pagina
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!!!!
lego halloween 2012.jpg
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!
Thanks for your instructions! I did not like working with the Styrofoam so for the girl, I did paper mache. I also used beer case boxes and the circles fit right it :)
we use yellow gloves
eacooper1 year ago
Great instructions, thanks so much! Our whole "lego family" had a terrific halloween.
Kaged Kombat (author)  eacooper1 year ago
Great idea with the bricks for the children! Such a good looking family!
Yes, the kids loved the idea of being lego men, but I was worried about visibility and tippyness, esp. for my 3 year old I think this was a better and more functional option!
sazzj1 year ago
Thank you! We made a couple of modifications here and there, but could not have made this without your awesome instructions! Our 5-year old LOVED this costume!
Kaged Kombat (author)  sazzj1 year ago
That's one happy Lego kid!
Great instructable - costume was fun to build together and was a big hit. Thanks!

Kaged Kombat (author)  MatthewTaylor1 year ago
I imagine he thinks you're the coolest dad ever now!
kwilcoxon1 year ago
My girlfriend and I went as Lego Bride and Grooms. Thanks for the instructions; everyone loved the costumes!!!
Kaged Kombat (author)  kwilcoxon1 year ago
You are now happily Lego and Lego, you may kiss the Lego. Great idea!
tedaii1 year ago
Great instructions! My middle schooler loved his costume and he had lots of people commenting on it.! A few things I noticed as building this: hot glue works better to hold the speaker fabric in place. I used adhesive spray to get the high density foam to stay (the gorilla glue seemed to want to soak in.) My son did comment on the paint fumes but we have it next to a heater to "bake" it a bit and see if they dissipate. This did not keep him from wearing the costume. We very briefly thought about using yellow duct tape (it comes in all sorts of colors now) but decided painting would give it a more uniform appearance. It did take me more then a weekend to assemble. Paint takes a bit to dry here where its' cool and damp. A great bonus: all the paint makes the costume water resistant which is important in the PacNW
Kaged Kombat (author)  tedaii1 year ago
I didn't consider hot glue, would be an alternative for the Velcro. The Gorilla glue does tend to soak in, but it expands and locks the foam together after a minute or two. Duct tape could be an alternative but you're right about having a negative impact on the uniformity. The paint fumes always seems to be an issue and I can't seem to find a better solution other than to use a brush on latex, which should have minimal odor. Sounds like he enjoyed it even with the stench. Always happy to hear of successful evenings!
Paint fumes were completely gone by today....we had finished painting 4 or 5 days ago. No problem. Vent hole was nice, the costume does get hot. LOL. My boys says people gave him extra candy for the cool costume factor. :-) Great instructions, could not have made this without some guidance.
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