The majority of this costume is cardboard and masking tape which is great because appliance stores are more than willing to let you take cardboard for free! I had a Lego man that I scaled up and just cut and taped the pieces once I had the measurements. For the head I used foam for the rounded edges of the top and bottom. I used a sanding block to round it and wrapped the middle with poster board. The mouth is a slit cut out that I used to see through. I used the poster board on the curve of the legs too. I cut the profile then taped it on the front. I used rope to make suspenders to hold up the legs. The hands were also foam and put on the ends of a cardboard mailing tube. Then all you need is a little paint! This is a must for any Lego lover!