2016 Halloween Costume Contest
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Hiro Hamada from Big Hero 6 Costume

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Hiro Hamada from Big Hero 6 Costume

completed. Paint didn't turn out like I wanted was a bit too humid when I tried but looked good enough to finish project.

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Photo #1 - completed. Paint didn't turn out like I wanted was a bit too humid when I tried but looked good enough to finish project. Photo #2 - original sketch design Photo #3 - my helmet designs  cardstock, cardboard and EVA foam Photo #4 - helmet re-designed Photo #5 - new helmet and armor build Photo #6 - armor together first run Photo #7 - redesigned gauntlets with stryofoam rings and foam insulation and some cookie sticks wrapped in thin foam sheet. Photo #8 - all pieces coated in mixture of wood glue and water to seal it all. Several coats needed makes it almost like plastic Photo #9 - Thanks and good luck on your builds
Costume type:  Costumes for Boys
Categories:Halloween Costumes, Movie and TV Show Costumes

This homemade costume for boys entered our 2015 Halloween Costume Contest.

A word from Larry, the 'Hiro Hamada from Big Hero 6' costume creator:

My son's favorite movie is Big Hero 6 and he wanted to dress as Hiro Hamada for Halloween. The store bought costume wasn't very good but after searching online I found some cosplay builders on Instructables.com and thought I would give it a try. Started the last week of Sept. finished it Oct. 24th. Started with the helmet first with cardstock paper then went to cardboard, and then went to foam. The helmet didn't turn out like I wanted original so 2 weeks in 10/9 started over on it. I had a deadline of 10/16 to finish building otherwise my son would have to get a store bought costume. Got a pepakura template never doing it before printed and cut it out then created a EVA foam cut out and did the entire helmet over. After than build his armor and found some Lacrosse gloves and created his gauntlets. Cut most everything out of EVA foam floor mats I got at Harbor Freight for $8 for 4 sheets. Gorilla glue and water mixture to seal everything up and prep for paint...took several coats. One mistake I did was not go back over and sand this down more. Glue will sometimes run or puddle so be sure to watch how much you use. After coating if will become harden so you can paint the foam...you can't paint until it is harden as the foam will soak up the paint. I used spray paint but you want to be sure not to do this when it is humid outside as the paint will not set right. Mine didn't on the big pieces. Next time I will Spray smaller area and use sponge brush to spread it. After that paint it you could coat with a clear coat if you like I didn't this time. My son loves the costume so his smile is worth all the time it took to complete. Now we feast on candy this weekend. Good luck to all those who want to be crafty and make their own costume. It is a labor of love.

Rating: 4.3 of 5. Votes: 3

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