For the past three years I have been building my own Halloween costumes.  The first year, I came across the website www.405th.com and built a Master Chief costume.  The next year, I came across the website www.therpf.com and built an Iron Man costume.   With two years of costuming experience, I wanted to do something different than the pepakura builds I had done.

So one day, I was talking to a friend trying to figure out what I should try to build next.  We bounced a couple ideas back and forth then he said, “what about a turtle from TMNT?”.  That idea stuck with me for a few days and I decided I would go for it.

First thing I did was to buy the TMNT dvd set.  I watched all the movies to refresh my childhood memories of the amazing films.  Then I decided which character best fit my personality, of which was Mikey.  So I had it figured out, I wanted to build a Mikey costume but had no clue how to go about it.

I did some research and figured the best approach would be to sculpt the entire costume.   Even though I had no experience at sculpting, I wanted something challenging.  My first sculpts were laughable. But with the encouraging help from members at the Replica Prop Forum, I was able to hone in on my sculpting and the improvements speak for themselves.   The RPF also lead me to a great friend who helped me complete this build, thank you Jacob!  Paint and professional photos by Jacob King.

The following instructions are a brief description of how I went about build this costume.  There are many other ways and different materials that can be used.   The hope is these instructions will inspire others to try something new.  For me it was sculpting, and now I love it!

Step 1: Materials

Material List
Most of the products used were from Smooth-on.  Great quality products.

Alja-Safe® Skin Safe Crystalline-Silica Free Alginate
Plaster of Paris

Chavant NSP Soft
EM-217 (WED) Clay
Sculpting tools

Rebound 25
Silicone thinner
Silicone thickner
Ease Release 200
Sonite Wax

Ease Release 200
Dragon Skin 10 fast
Ease Release 2831
Flex-foam it V

Bad-Ass! :)
<p>Tubular. Rad. Awesome. Cool. Where's the pizza, dude? :)</p>
<p>Amazing dude</p>
<p>Great instructable. Congrats on the win.</p>
<p>that's incredible, I tons of credit. It makes me wonder if other forms of the turtles can be done</p>
<p>oh my gosh, so detailed. i love it,</p>
Hi please would you consider in making one to sell as I want to surprise my son for his birthday his favourite one is Leonardo please can you help me my contract details are craighill98@googlemail.com
<p>this is very amazing. please check your messages.</p>
Costum is major sick!!!!!
How did you sculpt the face?
<p>Dericrw, this is truly awesome</p>
<p>Amazing job!!!!</p>
This is actually amazing!!!!! I'm an art student and wish I could make one but I don't have money for materials for this and for collage at the same time :/
Great job! You have a lot of money invested there. <br> <br>My Tae Kwon Do instructor (he was an olympic coach too) was actually Mickey. And yes, he taught me how to really use nunchuks as well as others.
I am awed by your commitment to this project. I didnt believe it when i saw it. I thought this had to be a joke. You did amazing!
Wow! That looks like a ton of work, but it definitely shows. This is the ultimate Halloween costume!
this thing is badass.
truly epic
Congrats on the win! amazing costume i looked at your RPF blog for pointers when i made mine. see ya next year!
Thanks Rexrothwell. Next year has already begun... lol
HOLY CRAP!!! thats just like the movie costume from 1990 ... when i was 8... the fact that now i see how it was made... i feel a little saddened by the reveal... it takes away from the movie hahahahaha BUT!!! IT IS AMAZING!!! good job man!!!
Thank you Licenseless! <br>
Kristylynn84: Thank you :)<br> <br> Rohtik: Awesome! Definitely give it a shot, but start small. Starting small will help you develop sculpting skills and get an idea of how far you want to go. Good Luck!<br> <br> SlippingHalo: It is a big project to take on, but a rewarding one. Look forward to seeing your take on the Turtles! Cowabunga
Damn, this is awesome. My brothers and I started working on this project this year, trying to figure out how to do it, and we ended up doing it almost exactly how you did! We ran out of time, so we're going to pick it up next year. Nice job!
wow. this is absolutely amazing. i will be making this next year definetly.
holy crap balls. you're gooooood.
Congratulations on being a finalist in the Halloween contest!!! Can&rsquo;t wait to see if you win! Good luck!
Thank you proofrabbit! It's an honor to be a finalist amongst all of the amazing entries.
how much of this life cast did u actually use to make all the body parts?
It all depends on the part your casting. You can save a bunch of materials by using or making a container that closely contours the shape of the part being casted. <br> <br>Here's smooth-on's guide <br>http://www.smooth-on.com/tb/files/Alja-Safe.pdf <br> <br>
I don't even...
Dude, as you already know, that is so awesome!! I had already started some concept design of my Halloween costume for next year. I was planning on making a Donatello costume with a combination of paper mache, panty hose, foam rubber, and liquid latex. After seeing your tutorial, I am seriously considering sculpting now. Durability is the big pro, but cost is the major con. <br> <br>Could you give me an estimate of what all of the materials costed?
Thanks zjarrell8. <br>I didn't keep an exact tally on the cost of materials. An estimate would be $5,000 USD, a partial reason for the high price would be everything was silicone. There are alternatives that are much cheaper, such as latex that you mentioned. <br>Good luck with your future endeavor!
This is absolutely fantastic! You have really nice craftsmanship, I'm inspired to delve into sculpting more. Thanks for sharing, this is a really impressive costume build.
Thank you Penolopy, poofrabbit, mike, and jessy! I'm glad that I choose Mikey! But the other three will be done in the near future.
Great job! Question about the bottom of the feet. If they are made of dragon-skin fast silicone, how durable are they exactly? I notice you are wearing them on the sidewalk and in other areas in the photos. Will they not show wear from being walked in?
Thank you! <br>The dragon-skin silicone is VERY durable! No wear at all in 10+ hours of wear. <br>
Oh my! It looks like you took it straight out of the movie!!! Amazing, amazing job, and, like everyone else, Mikey is my fav :D
This is awesome! Reminds me of the first tutle movies that came out, very well done!
This costume looks fantastic, and the detail of the skin really come through with this process. Mikey might also be a personal favourite.
I'm kinda freaking out right now. This is so amazing my brain can't process it. <br /> <br />Michelangelo is my favorite Turtle! :D

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