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.