Step 3: Cutting out the parts

Using the PDF I went to the shop and started cutting. EPS insulation board is pretty easy to work with, it is lightweight, and pretty cheap. Based on my plan I knew I would need 6 x 11" circles and one 6" circle from the EPS. I would also need one 8" circle of 2" foam. For the body I just used a tape measure to get dimensions of my son's shoulders and torso and sorta winged it no real plan on that one. The body was made from 1" EPS, the head from 1.5" EPS 

In order to get consistent circles and speed up the process I made a simple jig out of 1/2" mdf and a finishing nail.  With the jig in place it was easy to set the distance from the blade and drop squares of EPS onto the nail and spin perfect circles. For the top and bottom caps I also ran the discs through again at a 45 degree to remove as much material before I had to start sanding. I'm sure you could also cut the circles using one of the many 'ibles on hotwires as well, but I had a bandsaw so that seemed easiest.

For the inside circles I used the extendible exacto knife (i'm sure there was a better way to do this, but the knife was pretty fast and the inside didin't have to be perfect. 
Hi ! Love this costume! Just a quick question... The head is made from polystyrene ? U cut circles of polystyrene and the glued them together? And then the neck is made from foam? How did u round the polystyrene ? <br>
<p>I made a LEGO Indiana Jones for my son a few years ago too! So much fun!</p>
<p>Do you have the dimensions for your son? My son looks like he'd be about the same size as yours. Thanks!</p>
What's the best way to cut the circles without using a machine?
electric carving knife works well
There are a number of craft knifes you could use. I used an extendable x-acto knife for the inner circles, but you could use a &quot;hot-wire&quot; or a jig-saw blade. The foam is pretty easy to cut.
Great costume! Was just wondering what the foam squares are like and where can I get them?
Foam is 2' x 8' insulation board which can be found at HomeDepot, Lowe's or your local building supply store. It usually comes in Pink, Purple, or Blue. I just cut it into squares. It can be cut with a long box knife pretty easily.
Here a Pic! Thanx again!
That turned out fantastic! Great job. Hope the trick-or-treating goes well!
I absolutely love this design, look everything! Your Amazing! So, for my 5 yr son we gave it a try! but changed the character to a Lego city Police officer. Thank you so much for sharing..You made my son Halloween costume possible!
Grandiozo voy a hacer uni para mi hijo...!!<br>
I made a similar one for my son. The front is the screen so he could see and breath. I was a little hard for him to see but another boy helped him on the steps. It was fun, and we're already looking at something bigger for next year.
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So awesome! Here's how the one I did for my 3 year old turned out. Thanks for the great idea! I have photos of the build on my site: http://zanecochran.com/entry.php?blog_id=212
This is great! hope mine was helpful. How did trick-or-treating go?
It went great! He didn't have any overheating problems, but the head was a bit bulky, so after a while we carried it for him from door to door. The greatest thing was that everyone knew who he was, so it was a success! Thanks for sharing this awesome idea!
I LOVE Legos...and this costume is fantastic!
I have to say, my son was crazy impressed with this costume. He is slowly working his way through video game right now. Perhaps some black netting for the eyes and making vent holes out of the stubble to improve ventilation? Otherwise, this is perfect!
Thats incredible. You deserve alot of credit and your son must have had a ball!
That is fantastic!
ab fab!!
Maybe you could have paper mached the hat and face so the lighter weight material could be used? I don't know how it would do, but just an idea. :)
This is made of pure gold-pressed WIN.
Second to that!
This costume is EPIC!
Seeing this, I'm sure you could actually mod this so that there are different &quot;stickers&quot; you can apply and take off to change the face and body for anyone who wants to be able to reuse this and be a different LEGO character each Halloween.
Awesome, I'd reccomend a small 9v fan in the head to try and fix the heat problem though. 5 stars.
Yeah, just make sure you fix it very very securely....
Fantastic! If for whatever reason my kids don't want to go as Lego minis, then I will make it for me!! Great job!
Amazing. That is just amazing.
This is awesome! Very cool, indeed.
I am going to try this!
YESSSSSS! I love this! and its a lego that won't hurt like hell when you step on it with bare feet!
So freakin' good!
Nice work! Five stars.
Absolutely awesome. 5 stars.
Awesome! Getting your son's buy-in was critical; the fact that he ended up bailing due to being boiled alive is no reflection on the awesomeness of the concept -- you just have to do it better next year (this year?) :-)
Absolutely brilliant.

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