Voltron! Defender of the universe!  Definitely one of my favorite childhood toys.... so this year I decided to go big and try my hand at building a costume and also doing an instructable on it.
First i'd like to give a couple shout outs.... My girlfriend and our kids for putting up w my mess, madness and just plain craziness while I was attempting this. Love you guys soooooo much! They pushed me through this when I didnt think it was possible or if I could do it in time. Thank you, couldnt have done it w/o you.
Friends that pushed me through and came out to support me when I unveiled this thing at the contests.
Incrxtc and dannyeurena for giving me the Idea of building this and some great ideas and knowhow that goes with it.

I learned alot, and am very proud of how this whole thing turned out! I am already in works for my costume for next year.

I havnt seen an instructable on this costume yet, so thats partly why I picked it. I had actually started building soundwave as per Incrxtc, but wanted to push myself a little, and do something different.

Form Feet & Legs.... Form Arms & Body.... and I'll Form the Head!!!!

Heeeeeeeeeeere we go

*Note* Please see all pics as thats where you will find most of the visuals and instruction*

*Note* My camera was stolen on halloween night, so there are quite a few pics i didnt get to post, but I believe what I did have to work with will suffice anyone thats embarks on the journey of an Epic Costume!*

Step 1: Supplies & Workspace

I have some advice for you here... make a space where you can work and wont be in the way of everyone in your home, you WILL be making a huge mess. Dont use your dining table (and dont work on the table cloth your girl just bought to hide the table you ruined!)
Fortunately, I was planning on refinishing the table anyway wink wink! I also recommend if you have children, to put your work away when not working on it ( lets be realistic, if you woke up in the morning and saw this on the table as a 6 year old, you'd play with it too!)
As far as supplies go, you can use just about anything you'd like.
Heres what I used....

Sheet foam (Foamies brand or Creatology foam from Michaels)
Hot glue (I used 150 sticks at least)
Elastic or nylon strapping with buckles
Metal rulers or straight edge of sorts
Measuring tape
Xacto knife
Box cutter
Packing tape (after using this on my dummy parts, I quit using it and went to all glue)
Sharpie (asst colors if you have em)
Spray primer
Spray paint ( asst colors for your job, I use the $1 stuff from Wal Mart)
Plastic white mask
Under Armor or equivilent, long pants and long sleeve shirt. ( I will dye them silver)
Anything else you can think of that you may need or use...
Last but not least..... your Imagination in full force!
Hello sixsixzero! <br> <br>Just wanted to give you credit as one of the inspirations for my Voltron costume this year! Thanks for your instructibles! I wouldn't have been able to make mine without it! <br>I have to tweak mine a little bit since it wasn't that easy to move around in during Halloween. All in all though, it was a blast to make. <br>Thanks again!
You are most welcome. You are the second person who has actually built this costume and givin me credit for helping. I am just super stoked that it was good enough for people to want to try it and be able to succeed in using it. Glad I could be of assistance. Your costume looks great BTW, glad you followed through!!
Sorry, new to Instructibles. Here's a pic of my costume.
<p>What a great piece of art! </p><p>How do you keep the pieces for the arms and legs on? I have been examining your pictures and others from the web and I just can't figure it out. Is it just that the holes are snug enough to keep the pieces on when you put your arm/leg through or are they attached somehow?</p><p>Thanks for sharing :)</p>
<p>All of you Voltrons look AMAZING - I know what to do for the next Comic Con or next Halloween :)</p>
<p>I love what you've done!</p><p>I'm thinking of working with coroplast for a cosplay I'm looking at building due to the fact it's light and pretty durable. The only issues I'm going to have is painting and gluing it.</p><p>Am I right in assuming you just glued the coroplast with the hot glue gun and then covered it in the foam sheets to hide the ridged texture? And this worked fine without any prep work (like sanding down the surface etc)?</p>
I painted mine first before covering it in craft foam. I recommend giving it a quick scuff so the glue can really grip the plastic.
My email address is leowrick@live.com I would love the measurements I don't know how tall you are but I'm 6'1&quot;
Do you have patterns for this absolutely amazing costume I'd love to make it I used to idolize this show when I was a kid
I do not. I freehanded this entire costume. I can, however, give you measurements and answer any questions you may have. I did the same thing for a friend in Ohio, and his turned out really well.
Best. Costume. Ever.
You Rock Man!!! <br> I love Voltron! <br>It will be so cool if Voltron would be made into a movie like Transformer...
I would SO take my leg off and play with it like a lion! I heart Voltron!
Very nice, this is the best voltron thing I've seen in a long time, thank you for doing a good series justice.
This might be the coolest thing I've ever seen ever.
Bravo! Man, that came out so sweet! You need a mannequin to display that now.
Thanks man, that means alot coming from you!!! I am already trying to find a mannaquin btw!
Wow, fantastic job! I'm a huge Voltron fan!!! :-)
Thanks for the comments guys! Glad you like it and keep em comin! Any questions, just ask, I will do my best to answer any that you have.<br>Also, If you like it, and think I did well.... Vote for me plaease!
Which supplies would i need if i was to only do the head? <br>Also,how much would it cost?
The head is cardboard, and foam... thats it. No plastic or anything in this part.<br>Just depending on what you have already, I would say you could build the head for approx 10 bucks. The foam is only $1 per sheet, and depending on what paint you use, runs $1-$7 a can. Glue sticks are cheap, like $4 for 50 of them.
Thanks for the reply! <br>I hope this costume wins!
This is incredible!
That looks great! I'm so glad you didn't give up. Looks like it was well worth it!

About This Instructable




Bio: I just like to make stuff...
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