1st attempt at making anything like this. I got some complaints that his color was not right.... BUT at night it looks spot on based on the color code and closest materials found. its 2 inch foam ( next time thinner ) wrapped in duct tape and material hot glued to it.
the parts are all held together with velco and covered with material to blend in.
the head was a hard hat with foam formed and added some light s to make eyes glow. mouth is wide so he could have painted his face to look like the purple man inside...also safer to walk the streets since my area has little to no street lights to see.
the feet were an old pair of his shoes with foam, scrubbing pads and hair rollers.
Step 1: GETTING STARTED
GETTING FOAM LOOKING BACK USE A 1 INCH FOAM, WALMART HAS A GOOD DEAL ON ROLLS OF FOAM. WRAP THE FOAM AROUND EACH PART AND CUT. AND TRIM WHERE NEEDED AND ONCE YOU HAVE EACH PART TO AND TRIMMED START WRAPPING IN DUCT TAPE ( THIS WILL ALLOW THE GLUE TO STICK BETTER AND WONT BREAK DOWN THE FOAM AS FAST )
Step 2: COVERING PARTS
ONCE YOUR DONE CUTTING AND TAPING THE PARTS YOUR ON TO MATERIAL. MOST USE FELT I USED BASIC FABRIC. MAKE SURE YOUR MATERIAL IS AT LEAST 2-3 INCHES BIGGER THAN THE PARTS.
START GLUING LONG WAYS USE LOTS OF GLUE AND WORK YOUR WAY AROUND.
Step 3: ADDING VELCRO
ONCE YOU HAVE THE MATERIAL ON YOUR GONNA NEED TO CONNECT THEM ALL. PUT THE VEST/TORSO ON AND ADD EACH PART ONE AT A TIME MARKING HOW FAR APART YOU WANT THEM, ADD A MARK WHERE EACH VELCRO STRIP WILL BE.
ONCE YOU HAVE THAT DONE USE A BLADE TO SLICE AN OPENING WHERE THE MARKS ARE.
USE HOT GLUE IN THE HOLE AND THEN INSERT THE VELCRO ( MAKE SURE YOU ADD AN INCH OR 2 THAT WILL GO IN THE COSTUME )
Step 4: DETAIL
USE A MARKER TO MAP OUT WHERE YOU WANT TO CUT AND REMOVE. MINE I HAD SOME WHERE I REMOVED ALL THE FOAM AND SOME WHERE I CUT CHUNKS OUT.
ADD SOME FABRIC PAINT WHERE YOU WANT.
i USED AND OLD POWER CORD AND REMOVED THE WIRES AND CUT AND GLUED THEM IN PLACE.
I POKED HOLES IN THE AREAS I WANTED TO ADD LIGHTS , GLUED IN PLACE , CUT OUT A SPOT FOR THE BATTERY PACK AND GLUED IN PLACE.