How to Make a Giant Sandwich




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Hey everyone. Here you will learn how to make a giant sandwich costume. I know not everyone needs one, but I like to think people most want one. I built this for the awesome guys over at Naked Castle. As always we invite viewers to improve our design and send up video clips of your projects. All you have to do is upload, and you could be featured in our monthly user submitted podcast.

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Here's the complete video:

Shopping List

1. Two big pieces of cardboard. (These will act as the large surfaces of our bread. If you can't find a big enough piece you can tape smaller pieces together.)

2. A bunch of 1-1/2 inch thick foam. (I used about 3 sheets, with each one being about 3 feet by 8 feet.)

3. A big can of Foam and Fabric Adhesive Spray. (You might even need two.)

4. Spray Paint ( Cream, Black, Brown, Green, Yellow, Red) (A certain giant evil retail store, let's call it "Tal-Mart" sells all the basic colors for .99 cents. Good feeling in your soul sold separately.)

5. Gaffers Tape

6. Black Handerchief

7. 16 Wooden Paint Stir Sticks (I grabbed these when I was buying the Spray Paint and they gave them to me for FREE!)

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Step 1: Building the Bread

Keep in mind that you're going to have to do everything in this section twice. First thing you need to do is lay out a piece of cardboard and draw on your giant slice of bread. Make sure it's the size and shape you want. After you start cutting there is no turning back.

Step 2: Checking the Size

Make sure you check the size of the cardboard. A sandwich too small or too big is not good.

Step 3: The Crust

Now we can add our crust. Take some of our 1-1/2 inch thick foam sheet and cut long strips that are about 5 inches tall. You'll need an electric turkey carver to really get this job done right. Then using some spray glue attach our foam crust to the outer edge of the cardboard. Spray adhesive is a contact glue, so you'll have to spray both the cardboard and the foam. Let it dry enough to get tacky, then stick it together.

Step 4: Reinforcing the Bread

Next we're going to re-enforce the flimsy cardboard with some wooden paint stir sticks. The reason I used these is because they are fairly strong, light and most importantly FREE! I taped the sticks down across the inside of the bread.

Step 5: The Fixings

This is the part where you can get really creative. My sandwich ended up being a roast beef looking meat, lettuce and American cheese, but your sandwich can be whatever you want. It's time to take all those years of making edible sandwiches and apply it to a giant person suit. Lay out some more strips of your foam on the edge of the bread. Mark off the places you'll need to cut so that your foam lettuce, meat etc. fits right. Then start cutting! I really just started stacking everything on top of each other until it look right.

Step 6: More Stuff

Once you have the general shape, take some extra time to carve out some details. Little grooves along the edges of the lettuce made it look really cool. Now paint! Some one told me I had to use floral spray paint on foam, but regular spray paint works fine and is much cheaper!

Step 7: The Face (optional)

The guys over at Naked Castle wanted there sandwich person to be angry, but your sandwich can be happy, sad or even faceless. The angry face was a good way to hide a secret opening for the person inside to see out of. The secret is a black Handerchief. When glued in place on the front of the sandwich it just looks black, but from inside you can see right out. Like looking through a screen. The rest of the face is just poster board I stapled to the front!

Step 8: Putting It All Together

It's time to start gluing the heck out of this thing. This step is fairly easy and by far the most fun. Using generous amounts of our spray glue start at the bottom bread and work your way up. Glue each layer on top of the next. It's like making a real sandwich, but instead of mustard or mayo you're using toxic glue. Did I mention you should be wearing a paper mask when using glue and paint? Use a decent mask when applying large amounts of glue or paint, even if your outisde.

Remember, someone is actually going to wear this monstrosity. Stick together 3 long pieces of gaffers tape and you've made some pretty strong cloth straps. Once the sandwich is put together, crawl inside and tape each end of your straps to either side of the bread. When your done you should have 2 shoulder straps that keep the sandwich in place.

Congratulations, you're now the proud owner of a ridiculous costume. Please post your questions or comments.

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    47 Discussions


    8 years ago on Introduction

    So now that we can make a giant foam sandwich, the next step is making one we can actually eat!

    1 reply

    Reply 5 years ago on Introduction

    ...Or sleep in! My god, this could be a bed if you'd fill it up with foam! Or a sleeping bag!



    6 years ago on Introduction

    This is great, I hope some more people see this instructable and make this! It would be perfect for the new Cloudy with a Chance of Meatballs 2!


    10 years ago on Introduction

    or remove all of the every thing else besides the bread and spary a little collor on and you got toast


    10 years ago on Introduction

    wow I am impressed! this is awesome, the fact that you would do this is super creative and spectacular!


    11 years ago on Introduction

    ---First - I LOVE IT! Funny creative people RULE!!! Now, for some questions: 1) Does this come with fries? Or chips at least? 2) how about a floatable version for pulling behind a boat? I can NOT waterski; tried; failed; repeated. But I'm certain a sandwich would never spit ME out! The kids would love riding in it and I've seen way stranger things (my friend pulls around a shrek's-head type device with like 10 kids inside and it's clearly fun for kids and hilarity for the onlookers and parents) 3) Perfect April Fools day gag for the family - replace all the beds in the house with XL sized bed sandwich, which is what I thought it was when I clicked the link. Thanks for being bold, funny, creative, and sharing this!


    12 years ago on Introduction

    You could make a cool bed if you mad the bread a mattress and made it a bit bigger. The bedding on the bed would look a bit weird if there was any patter what so ever on it but if you had white bedding you could make a pretty nice bed! I don't know, just a thought. You would have to change it a lot though. Coolio idea though! :-) {laura}

    1 reply