Step 1: What You'll Need.
Here's the shopping list, along with approximate prices. Note: The Pool Noodle and Camping Waist Pack are missing from the photo below.
QTY. - ITEM DESCRIPTION - PRICE
2 - 15 qt. Oil Drain Pans - $8 each
2 - Small Ice Scrapers - $3 each
1 - Mini Backpack - $9
1 - Camping Waist Pack - $8
1 - Car Cupholder - $2 (enough for 5 costumes)
1 - Large Pool Noodle - $1
LOWE'S / HOME DEPOT
6 ft. - 3/4" PVC pipe - $1
4 - 3/4" PVC 90 degree elbows - $1 each
1 - 4 Tier Black Plastic Utility Shelf - $24 (enough for 6 costumes)
1 - Grey Electrical Conduit Junction Box - $3
1 - 3" long nut with bolt + washer - $1
1 - Pack of Black Zip Ties - $1
THRIFT STORE / YOUR CLOSET
1 - Pair of Pants (light color is better)
1 - Pair of Shoes (light color is better)
1 - Bike Helmet
PVC Cement + Primer
1 - Safety Vest (Segway tours wear safety vests sometimes, and it looks funny)
Step 2: Cutting the Platform.
The shelves will become the platform of the segway. First, take one of the shelves and cut it in half. After it is cut in half, cut a rectangle out of the cut side, about 6 inches deep. Leave the side walls of the shelf. You should end up with a sort of U-shaped piece.
Step 3: Drilling the Post.
Step 4: Assembling the Handlebars.
The post from the previous step is combined with the mini backpack, 2 small ice scrapers, and car cup holder to make the handlebars. First, put the 3 inch bolt through the hole in the ice scrapers (mine came with a hole in them, but if not drill a hole). Next, slip the bolt through one side of the hollow post. Then, catch the top loop on the mini backpack around the bolt before threading it through the opposite side of the hollow post. Finally, add the cupholder (which also had a hole in it). Tighten the washer and nut to secure the assembly.
Step 5: Adding the Handlebar Base.
Step 6: Attaching the Handlebar to the Platform.
To get a secure connection between the conduit box and the platform, zip tie them together. First, drill 6 holes in the conduit box, 3 on each side. Then drill 6 holes in the platform, adjacent to the 6 holes in the conduit box. Loop three zip ties through to connect the two parts, and tighten down. Be sure to really crank down on the zip ties to get a secure connection.
Step 7: Building the Fake Legs.
Step 8: Dressing the Fake Legs.
The pool noodle, pants, and shoes will dress the PVC "skeleton" to make the fake legs look real. First, cut the pool noodle in half, and slit it up the side using a utility knife. Then, slide the pool noodle sections over each PVC leg. Next, put on the pants and shoes. Finally, trim any excess pool noodle that sticks beyond the PVC waist.
Step 9: Attaching the Fake Legs.
Step 10: Trimming the Wheels.
Step 11: Attaching the Wheels.
Step 12: Attaching the Waist Belt.
Step 13: Finishing Touches.
Your Segway costume is almost done, but there are a couple finishing touches to make your costume even better.
1. Tape some padding to the inside of the U-shaped platform. Your shins will bump up against this occasionally, and the hard plastic can be a bit sharp unless you add some padding.
2. Secure the tops of the wheels to your fake shoe shoelaces with zip ties. Otherwise the wheels will have a tendency to flop down a bit.
3. Wear black shoes and pants on your real legs, so that they aren't as noticable as your lighter colored fake legs.
4. Be sure the waist belt is really tight. The tighter it is, the more comfortable it will be to walk around.
5. Add some details! We added paper "Chicago Segway Tour" signs along with matching bike helmets, and safety vests. My friend below was the tour guide, so we put an orange flag on his Segway.
Step 14: Roll-out and Enjoy!
Clip the waist belt around behind you and you are riding your Segway! Many people thought that we were riding real Segways, even when we were indoors. Because the costume is so easy to get on and off, it also makes a great photo-op for other people to try it on. We had such a great time this Halloween, and we received lots of compliments on our costumes.