The Kragle costume is made from a 2-pack curtain set that my wife and I picked up at Walmart. The nice thing about the set is that it's about 5 feet high and 2-1/2 feet wide which is almost perfect for making a 'tube' by joining the two pieces together.
The curtains have a nice hem in them on both sides that resembles the Krazy Glue's tube "turn up" from the bottom of what would be the tube.
At the top there's a hem that you would normally stick a curtain rod through. There's just enough space in the hem to stick in some water pipe insulation to give the top of the tube a bit of mass and texture.
Step 1: Bill of Materials
While this list is far from complete, it'll be enough to get you started.
Ownes Corning Fomular foam insulation boards - 1/2" or 1" thick.
Gloss red spray paint for plastic
Kilz water based primer
Blue painter's tape
Plastic drop cloth
Foam pipe insulation
Green fabric paint
Red fabric paint
Various paint brushes
Window Curtains (specifics to come)
Hot glue gun and glue sticks
4' straight edge
Computer & Printer
Inkscape -- http://www.inkscape.org/en/
Krazy Glue pictures for reference
Step 2: Print, Trace and Fill in the Krazy Glue Logo
I started out by downloading a vector image of the Krazy Glue logo and printing it out to the size that I needed. You can find a vector image by searching "krazy glue vector image". I used Inkscape (a free vector editing tool found at http://www.inkscape.org/en/) to print the logo. The logo letters are about ten inches high for my application. You'll have to print the logo out on multiple sheets of paper as shown and then tape them all together. After taping the paper down to the floor, we taped the curtain over the logo and then traced out the logo with pencil. Of course you don't need the ZY or U from "Krazy Glue" so we didn't trace it.
Before painting your curtain, be sure to put down some cardboard or a plastic drop cloth. The fabric paint will bleed through the material and ruin whatever you have underneath.
Step 3: Messing Up Most of Your Hard Work
Of course, the Kragle has lots of really worn areas on the tube that makes it look well used. Unfortunately, if you want to be super authentic, you'll have to emulate those areas by painting over a lot of your hard work with white or silver paint. My wife chose silver paint as the Krazy Glue used to come in a foil tube that was printed white and green.
As you can see the areas look worn. She was a bit sad because the Kragle wasn't new and shiny any more!
Step 4: Top of the Tube and the Threads
Of course, my wife needed some way to wear the costume. I cut a doughnut out of thin plywood (luan board would do fine) with a diameter of and an inside diameter of . To make the plywood more comfortable, I cut some padding from an old camp mat (see my Emmet Lego Costume instructable) and glued it to the underside of the plywood. Her shoulders are much more comfortable now.
We found a straw basket at a thrift store, cut a hole in it big enough for her head and painted both the basket and the plywood silver. I think the basket gives the illusion of screw threads without having to go through all the trouble of making the threads. If you want to go through the trouble, cut some pipe insulation in half and glue the 1/2 moon shapes in a helical pattern onto the basket.
That's me in the picture BTW!
Step 5: Making the Piece of Resistance
The Piece of Resistance is just a piece of Owens Corning Fomular insulation board that we cut into a 12" x 24" box. A hot glue gun set on LOW will make easy work of constructing the box. Don't use high heat or the glue will melt the foam board.
At the top of the box I put in a 11" x 11" 'capper' that completes the look of the box.
You must coat the foam board with a water based primer before you attempt to spray paint it. The propellant from the spray paint will eat away at the foam if you don't. I did have a bit of deterioration but it's nothing major. I used Kilz water based primer that I had left over from painting I did earlier in the year.
After the paint is completely cured (I recommend two days) I glued some more camp mat into the open end of the box so that my wife could wear this as a hat. You'll have to customize the "hat" section to your head size. After that, I glued some 2" Velcro to each side. I got the Velcro at Harbor Freight on sale for $1.00.
Step 6: Construction
My wife used heat sensitive tape and an iron to glue the sides of the curtains together. We attached the top of the curtains to the plywood doughnut with zip ties. The basket is attached with hot glue.