This year (2008) my kids wanted to be Buzz Lightyear and Sheriff Woody. This instructable focuses on the Buzz costume because it required a more unique, creative approach.
Step 1: Chest Piece Structure
I borrowed one of our garden planters and used it as a mold to build up the basic chest structure. The chest piece is made of cardboard, duct tape, masking tape, hot glue, and paint.
I cut, shaped and sculpted as I went.
Step 2: Chest Piece Details
Details were added to the chest piece with more cardboard, foam, and tape.
The jet pack and wings were also built at this time.
I spray painted the entire thing white, and added details with colored craft paint. The entire thing was given a coat or two of lacquer to make it shiny.
Step 3: Leg Pieces
These were made from two small sports cones, cardboard, and the bottoms of four yogurt cups.
All the pieces were hot glued in place, and the entire structures were primed and painted.
Step 4: Arm Pieces
The upper arm pieces were made from pieces of flat cardboard that were curled and glued together to form a tube shape.
The forearm pieces were made from cheap plastic cups--the kind that kids get at restaurants. They were cut and shaped with a sharp utility knife and scissors.
Details on these pieces were done with sharpies, paint, and colored pencils.
Step 5: Hood
The hood was made from purple polar fleece.
I had to make up a pattern for this part. The first attempt was close, but not quite good enough. So I added a little where needed, and the second attempt gave me something better.
Step 6: Finished Costumes
Buzz's costume was completed with a black sweatshirt, and white pants.
Woody's costume was fairly simple, although the shirt, vest, buttons, star, belt, holster, and spurs had to all be made. The boots were originally pink, and the hat was orange. Some brown spray paint fixed that.
The costumes were a hit with my kids, and all the neighbors got a kick out of them as well.
I was the popular Dad this Halloween. Boo-yah!