UP: Carl the Old Man Costume

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Introduction: UP: Carl the Old Man Costume



This is the main character Carl from the kids movie UP.  Its cheap and easy to make plus its a costume most people know that also stands out in a crowd.  

Step 1: Materials

 For materials I used a box, paper mache, faux fur (hair), paint, paint sticks (frame for glasses), electrical tape, chicken wire, wire cutters, masking tape, wiffel balls (eyes), wood glue, and went to a thrift store for the outfit.

Step 2: Foundation

To start I found a box big enough to fit over my head and rest on my shoulders.  A box works well because the basic shape of Carls head is square.  I covered the sides and top with chicken wire leaving a round edge for Carls big chin.  Chicken wire works well because it is easy to shape and mold plus its strong.  Then I covered everything in masking tape because the paper mache wont stick to the wire but works well with the tape.  leave a hole for the nose, ears, and a ridge across his face for the eye brows.  Be careful when cutting the chicken wire, sharp edges can form and may prick you.

Step 3: Ears

I molded the ears out of chicken wire and attached them to the sides of the head.  To attach them I just spun the excess wire around the wire on the side of the head like bread ties.  Cover it in masking tape.

Step 4: Nose

just like the ears, I made the nose out of chicken wire and attached it to the wire around the box where his nose should be.  I spun the excess wire around the cage like bread ties again. The nose should be oval and once its attached just squash it down a little bit.  Then cover it in masking tape.

Step 5: Details

I drew out where his eyes and wrinkles should be using a pen.  For the wrinkles and eye brow ridge I took strips of masking tape and rolled them up into cords with the sticky side facing outside.  Then I placed them on the wrinkle lines and eye brow ridge to give the details some depth.

Step 6: Eyes and Paper Mache

I cut a wiffel ball in half and used it as the eyes.  I used masking tape to hold it in place and to give Carl some eyelids.  I also used  more tape to create more depth in the cheeks and wrinkles.  The next step is paper mache.  For this step I used a mixture of 25% wood glue, 25% flour, and 50% water.  I also used strips of paper towel because its stronger and easier to fit in the detailed areas than newspaper is.  Let this step dry for about a day and a half  then you may need to apply another layer.  I only used one layer because I had 3 days until Halloween.  Also, be careful cutting the wiffel ball, due to the shape of it and the fact you are using a knife/scissors its dangerous.

Step 7: Paint

The paper mache was dry in about a day and a half.  I also placed a window fan on Carl to speed up the dry time.  Next, I painted Carls head with acrylic paint.  I used a color called "Santas Flesh" for the face and "Cocoa Gold" for his hearing aids.  I used blue nail polish for his eyes and a black permanent marker for his pupils and mouth.  

Step 8: Hot Glue His Hair

Next, once dry, I measured his head and applied the hair (faux fur) accordingly.  I applied the hair to his head using a high temp hot glue gun.  The gun is extremely hot and can cause bad burns so you should use caution with this step.  Next, I painted the wiffel balls and cut out a 2 inch gap between his eyes and under his eyebrows.  This gap is for my vision when wearing the costume.  Dont cut the hole too big yet because Carl wears glass and the hole me be blocked be the frames of the glasses.

Step 9: Glasses and Eye Brows

When buying the paint I also asked if I could take a bunch of free paint sticks which happened to be the perfect width for Carl's glasses.  I broke up some to make the boxes and used whole paint sticks for the long part of the frames that attach to his ears.  I then covered the frames in black electrical tape.  Electrical tape works well not only because its black but its shiny.  Then I used the scraps of my faux fur (hair) to make the bushy eye brows and I attached them using the hot glue gun again.  Lastly you can now make the eyesight hole as big as you need to see.

Step 10: Safety

The parts you need to use caution on while making this costume are with the hot glue gun and cutting the chicken wire/ wiffel ball.  When you cut the wire it leaves sharp edges so make sure you bend them in a way that they do not stick out or can poke you, especially ones that may penetrate the box and stick you while wearing it.  Check carefully, you can cover these edges on the inside with duct tape.  

Thanks for reading, maybe next year I can find a Russel, make Kevin (the big bird), and dog sit my friends golden retriever for the day.

Halloween Epic Costumes Contest

Finalist in the
Halloween Epic Costumes Contest

5 People Made This Project!

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31 Comments

0
Flamel777
Flamel777

7 years ago

Should the faux fur be used on the back of the box?

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lsdj
lsdj

8 years ago

???

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wmorey37
wmorey37

Reply 8 years ago

No, paper mache needs 24 hours to dry

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lsdj
lsdj

8 years ago

Think I could do this In a day

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abbey.dinner
abbey.dinner

8 years ago

I am making this for Halloween this year! Where did you buy the faux fur? How much did you find you needed? I couldn't find the same paint colors you used but I found some flesh looking ones. I have everything I need except box, fur, electrical tape and cane with tennis balls! Any help or suggestions would be awesome!!

0
wmorey37
wmorey37

Reply 8 years ago

I bought the fur at Joann fabrics. They actually ran out but a lady waiting in line over heard me talking and gave me hers. I only needed about a yard of fur. You should measure your box first to be safe.

As far as the paint colors go. I just randomly picked fleshy colors so dont worry about that.

Suggestions: the fur is the most difficult to find. Go to any fabric store asap. They sell boxes and electrical tape at home depot. Also ask for paint stirrers there. They are free and the lady working gave me 10 for free. As far as the cane goes you can use pvc pipe or cardboard dowels which are also sold at home depot. I had a friend that was a nurse so she grabbed one for me at her hospital. You can also search thrift shops and second hand stores for canes. I have seen them before there. Go to the salvation army and buy a brown 10$ suit to wear. Iparty for balloons and search for a promo code for balloon sales. You should be all set if you fall the instruct able.

Thanks for viewing mine, Good luck.

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abbey.dinner
abbey.dinner

Reply 8 years ago

Great! Thank you! I did remember to get the paint sticks at lowes improvement. I will work today at getting the fur. Joann had some but they seems too beige tinted. Thanks for your help! I hope it comes out somewhat decent. Ha

0
RyanO2
RyanO2

8 years ago on Introduction

how did you shape the chin? In that picture you can't see very well

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scott_pocket
scott_pocket

9 years ago on Introduction

so it was just your head in the mask? did it slide all around and did you have to hold it all night?

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wmorey37
wmorey37

Reply 9 years ago on Introduction

Ya, it was just my head and a big open box. I made the costume last minute. usually I would stuff the head with bubble wrap and secure it with a tape or glue. The box was big enough so that it rested on my shoulders all day so it was too bothersome.

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poofrabbit
poofrabbit

10 years ago on Introduction

Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!

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auntylulu
auntylulu

10 years ago on Step 9

This Looks Awesome.Thanks for Sharing. I just finished making a big Guinea Pig head for my son's costume and kept thinking I should have use some sort of wire mesh. Do you think thinner mesh ( like wire mosquito screen) will be modable and hold the shape?

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wmorey37
wmorey37

Reply 10 years ago on Introduction

I have never used mosquito screen. The aluminum mosquito screens that I have on my house are older and after looking at them I dont think they would be suitable for large heavy projects. The chicken wire that I used is galvanized and much stronger than what I need it for, I just use it because you can mold it easily and it would almost always hold form. I actually have dropped Carl's head several times over Halloween and he is fine, just needs some touch ups. Also, I really just need the wire to hold form until the paper mache dries. If you use a few layers, especially with paper towel strips, the sculpt will be solid. For my splinter costume I actually removed the chicken wire once It was finished drying. I know home depot also carries chicken wire in different sizes and lengths so you can find some close to the size of the mosquito screen. I hope this helps,

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atyk
atyk

10 years ago on Introduction

This is the best costume ever! It's adorable! Now you need a little Russell to go with it :)

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MarkML
MarkML

10 years ago on Introduction

Great job! It came out great. Good job finding inexpensive materials.