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Common materials needed:
Hot Glue (loads)
Faux fur fabric
Solid Coated Wire (12 gauge)
Lycra Pants & Shirt
Nuts and Bolts
Not so common materials:
A Little Tikes toy chest shaped like a ball
Football Shoulder Pads
Step 1: Fatten Up
So I made a fat shirt and fat pants.
Basically foam hot-glued over Lycra in an "armor" type fashion. All you need is a dummy to fill both the pants and shirt so the Lycra is stretched when you hot glue it. If not, the foam will a rip off when you put the suit on.
I used a duck tape dummy and thanks to ModMischief I knew how to make one!
Step 2: Paws
Pretty much the same as the last step. Although being a bit ambidextrous is good when doing your dominant hand.
Step 3: Sculpey
For the horns and nose though, I had to make a base sculpture out of aluminum foil to lessen cook time, keep the weight down, and keep from wasting a lot of money on a lot of sculpey. (you can see the aluminum under the sculpey)
Step 4: Head
I cut holes for the mouth and eyes, screwed down the lid and cut a hole in the bottom for my head to go through.
Then added screen mesh to cover the mouth and mask off myself inside. (in the pic you can see that some of the spray foam dripped down onto the screen from around the eyes. Make sure spray foam dries first!)
I used harder foam for the lips that I hard from an old Pelican camera hard case, they were added after all the cutting and also the nose and horns, mounted with screws from the inside out into the bottom of the horns, as well as epoxy on the outside.
I used Plasti-Dip to coat the inside of the mouth to make it more mouth-like, and to help secure teeth later. I took three coats, about a whole can, to get it smooth. The Plasti-Dip soakes into the foam a lot, but I wanted that for later when I cut a slit for the teeth, makes it look more like actual gums around teeth. (you can see the shininess where the Plisti-Dip is on the lips)
Step 5: Eyes
and painted the insides to look like pupils.
To paint the insides, I took a round cup, traced the circle onto the globe with a dry erase marker and then used acrylic paints for the pupil and whites. It's different because you have to work/layer colors backwards. It takes a while to dry too.
Then they were mounted with a few pieces of duck tape to position them, then spray foamed in to secure them completely. You can see the yellow foam coming through the cracks from the inside. Again, make sure the spray foam dries before tilting it right-side-up or the foam will drip down and you have to clean it off your screen mesh where the mouth is, you kinda need to see out of there.
Step 6: Head Mount
I cut the 1/2" thick wooden disc mainly to hold the head, but it also needed velcro around it to attach the fur suit later on.
Sandwiched between the bottom of the wooden disc an the plastic base of the toy chest I had two metal plates with holes drilled in them for extra stability. An extra nut for spacing and a couple lock washers help as well. You can see this in the new photos.
Step 7: Claws
I'm not gonna go into the sewing process, if you look at normal winter gloves, you can just mimic the pattern. That's what I did and I am no master at sewing!
Step 8: Tail
I started with the upper and lower eyelid pieces and then just worked my way out from there.
My wife was Max. She made her costume too! I have to give her a shout-out for putting up with all this and for sewing my fur suit while I worked on the other elements! :)
All the parts piled together. The suit was not terribly difficult, mostly sewing from measurements off my fat suit, trying it on, re-sewing, try it on again...I got hot.
The whole suit is sweltering if you plan on being inside a bar or anything like that! Stay hydrated!
It was a fun night out on Halloween nonetheless.