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First off, there are some wonderful instructables on mascot heads that are more informative then mine, so if your looking for a more informative instruction on head mines not the page to find it.
We started the costume with the idea that a latex suit was out of our realm of expertise, and expensive. Fabric and foam was easily accessible to us and we felt instructables could help us with some guidance. So this instructable is kind of paying this great site back.

Step 1: The Head

First off, there are some wonderful instructables on mascot heads that are more informative then mine, so if your looking for a more informative instruction on head mines not the page to find it.
We started the costume with the idea that a latex suit was out of our realm of expertise, and expensive. Fabric and foam was easily accessible to us and we felt instructables could help us with some guidance. So this instructable is kind of paying this great site back.

Step one: we had 6" foam blocks that we glued together ( homedepot sells 2" you can glue together) to get the right size. We drew up a template of the front and side of the head. And also traced our head to insure we don't make a turtle head too big or small. You can use a grinder with a sanding disc and a hacksaw blade to cut off the styrofoam you don't need but you must wear a mask and safety googles. The foam goes everywhere. After rough cutting your shape you next sand by hand to get your exact shape. When your happy you can start gutting the inside like your carving a pumpkin to the exact shape your head can fit in. We cut the mouth out to see and also cut a slit just under the bandana to see which help immensely. Cover the head with spray adhesive and any stretchy material of your chose.

Step 2: The Body

Step two: the body was made by making a wire "cage" around our body that can be welded or duck taped together. Make it as tight as you can without making it impossible to take off or get on. The shell was made almost the same way as the head, foam, shape to size, sand etc. We bent some wire and pushed it through the foam till it came out the other side and we welded it to the frame. Painted the shell black and covered the frame with cardboard and duct tape. We glued packing foam to the outside of the shell to give some added depth to the shell and dry brushed brown to it. Cover the cardboard with felt. It's cheap and looks nice. When making the belt remember paper templates are cheaper then cutting fabric thinking the belts just a straight shape and finding out you just blew $10 because the body is not a cylinder shape. You may want to make straps to hold your shell on, mine fit great till I started walking and sweating. Then the shell started falling.

Step 3: The Arms and Legs

Step three: the arms are EVA foam that cost $11 for a 4x6 sheet. We got two arms and two legs out of a sheet and a half. I wish I had a better explanation to making the arms and legs then just saying copy my pics and work it out. There are weird shapes that make up both parts so if you can't figure it out by looking over the pics email me and I'll try to help you as much as I can.

Step 4: Finished Pictures

Hope this helps somebody. I'll edit as the questions come in. I missed a lot of info like the hands, weapons foam elbow and knee pads. But as I get some free time I'll keep updating this page.
Thanks for looking
Awesome job. How did you get the legs and arms to stay on. Or are they form fitting enough not to slip around?
<p>Thank you my cozen loves TMNT and seeing this at his party he'll go nuts thank you </p>
<p>I LOVE the 2012 TMNT series. Going on the To-do list. </p>
Great job!
Cool ideas. I like the cage form. Solid, light weight and easy to maneuver.
Should probably tell these people about copyright protection before putting out on Internet.
<p>selling copyrighted costumes is illegal. Making them for the enjoyment of your friends and family is NOT illegal and you should be fine. </p>
<p>Really great costumes. Not sure I could make one from your instructions, but I am impressed. Using the armature is a really good idea - you can keep the costume relatively light and yet it will be more robust than just the foam. I do have two questions: You obviously had reference photos, but did you do a lot of design sketches too - profiles, measurements, etc? And for the thigh portions - are those tights or did you construct legs from the same material you used on the feet? I really like the finished costumes.</p>
<p>I sort of &quot;eyeballed it&quot; with proportions. A lot of building in my head and the legs are sweatpants sewn tighter then usual. The feet are couch cushions great stuffed to old sneakers. </p>
<p>These are super impressive!</p><p>I would love to see more info on how you did the hands, weapons, and so forth. If you add some additional steps and details, that would be really nice. These are so cool! </p>

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