I transformed my 5 year old son into the leader of the Monster Realm - Lord Vampyre from Lego Monster Fighter series.
The costume is 100% handmade using mainly a low density PVC foam board called sintra and joints were filled with Bondo. Styrofoam was used to sculpt the hair and the beveled rim around the head. The costume was spray painted and graphics were created in Adobe Illustrator and printed on adhesive vinyl. The only tools required for this costume were 2 types of x-acto knives, 1 heavy and one scalpel for circular cuts, a heat gun for curving the sintra foam board, a metal ruler, some clamps (optional) and a rasp for shaping the detail in the hair. Industrial adhesive was used to glue together the sintra. (E-6000) as well as PL Premium and a little hot glue.