- Cereal Box Cardboard
- Masking Tape
- Blue Fleece
- Blue long sleeve shirt and pants
- Fabric adhesive
- Hot Glue Gun & sticks
- EVA foam (1/2")
- Craft Foam
- Elastic Strips
- Red, White & Gold spray paint
- Face Paints
- White Gloves
Step 1: Planning
Step 2: Basic Head Shape
Then I made another strip to go along the back of the head and taped it up to the head band. This will help the helmet to be more stable an not wiggle around when he moves.
Now you have the basic foundation to build the rest on. I also added the shape for the eyes. I had my son put it on several times to get the placement and size right
Step 3: Building Up the Head
Next add more cross pieces checking shape and size. Place support pieces to keep it from collapsing. From there, keep adding pieces to connect it all together. On the next step, I cover it all with masking tape, and the more cardboard there is the sturdier and round it will be.
I had my son try it on multiple time to make sure it fit and the shape was right.
Step 4: Add Tape and Ears
After it is covered, add the ears. I drew on the position of the ears right on the tape. Then I used cardboard to make ears. Again, measure the right size. I cut the front piece first for this. Then I measured the side pieces to custom fit the shape of the helmet. Tape it together and to the helmet.
Step 5: Cover With Fleece and Add Spikes
I don't have any pictures of the process, sorry. Basically, we draped the fleece over the top of the helmet. Then we cut holes for where the ears were. Make small slits for this as the fleece is pretty stretchy. Then once we had it well positioned we sprayed on the fabric adhesive. Then, hot glue the edges to the underside of the helmet. Then cover up the ears with the same process.
Now for making the spikes. This is a basic cone shape sewed together. However, because Sonic's spikes don't stick straight up they have to be curved a bit. We tested this with paper first to get a template before cutting the fleece. Once formed, stuff them with batting (we used an old pillow). Then hot glue the spikes in place. Start at the top and work your way down making sure to stretch the fleece tight. Do this for all the spikes. The front spikes are bigger than the back spikes.
It's not in these pictures, but we also glued pink fabric triangles for the inside of the ears.
Step 6: Shoes
Then I also cut out the buckles from the EVA. From the craft foam came the white stripe. I spray painted them all their respective colors.
I glued all the pieces together using hot glue. I also included elastic straps to help keep it on to my son's shoes.
Step 7: Pants and Shirt
Then we (my wife) sewed on the big flesh colored oval to the shirt. It looked great.
Step 8: Put It on and Look Awesome!
Unfortunately, the design of the shoes slowed him up a bit, but at least he looked super awesome!