I created this costume for my son. We ordered a few mascot to promote our business and they were way to big for him He wanted Sonic but it was over $200 online. I decided to try and make it myself. This is the first costume I have made from scratch. My husband and I own a Halloween store so I have been working on more homemade items. www.JJsHalloweenoutlet.com
Step 1: Step 1 to Making the Mascot Head
I used a cheap punch balloon and covered in with paper mache. I did this over several days; allowing it to completely dry in between layers I used a fan to speed up the process.. Then after popping the balloon I cut the hole in the bottom for your head. I drew the face on with marker just to get a good idea of where everything would be. I also cut out the eyes where you would be looking out of.
Step 2: Step 2 Mascot Head
Next I cut slits in the head for each spike Sonic had. 6 total; 2 on each side and 2 on the top. I reinforced these with cardboard. I also reinforced the head opening with duct tape. I cut foam strips and put them through each hole. I hot glued each one in place.
Step 3: Step 3 Mascot Head
After the spikes I added the ears, these are just 2 pieces of foam cut into triangles and again I slit the head to put them in and reinforced with hot glue. Then I took regular batting used for making quilts and hot glued it over the entire head...spikes and all. This helps to smooth everything out. After the batting it all looks like one structure. I drew the face on again just to get a good sense of everything. I cut the eyes out again and glued the excess inside. *NOTE: make sure the eye holes are big enough. I had to go back after the costume was complete and cut them large because my son wasn't comfortable with his vision.
Step 4: Step 4 Mascot Head
I purchased blue felt fabric, about 2 yards at $3.99 a yard. I covered the entire thing with fabric, making sure to keep the seams on the sides and back. I ended up hand sewing the fabric around each spike and it turned out a lot nicer than just using the glue. I hand cut the arches where the eyes are and glued a piece of craft foam under the blue felt.
Step 5: Step 5 Mascot Head
I recut the eyes. You can see how small they are. They ended up being about twice that size. I purchased 1 yard of fabric in the tan color and cut the detail for the ears and sewed a long oval with foam in it for the snout. I used a black pom for the nose and thick black string for the mouth, I ended up hand sewing the snout on the sides so it didn't stick out so much.
Step 6: Step 6 Mascot Head
I used a sheer black fabric for the inside of the eyes and glued it to the inside of the head. Then a black oval around the eye and a green oval that fits inside the black one. I cut these using my cricut but I'm sure you can buy something like this already done at a craft store. I used a paper hole punch for the white detail of the eyes. I used hot glue to glue it all on.
Step 7: Step 7 the Body
As far as the body I am not a very experienced seamstress. I got a pair of my sons pajamas and laid then on the table. I set the fabric on the table and cut it a little larger than his pajamas. It turned out fairly well. I sewed the stomach like a round pillow (no filler) and then glue that on so there wasn't a seam anywhere. For the tail I sewed a cone like shape and added some foam inside so it would stick out a little. I also ended up adding an additional spike off the back of the head. I hand sewed that on as well. I didn't have any intention of adding the sleeves. I was just going to buy a shirt that color but I had the fabric already so I gave it a shot. The seams are a bit though. We took shoe covers from another costume and bought some white gloves. I also sewed the white cuffs on the pants and sleeves.