Lego People Costume

My boyfriend and I always go big on Halloween. We like to create our own costumes and enter contests. This year we wanted to do something big so after a long search we decided on Lego costumes. I recreated the bad cop from the Lego movie and my boyfriend was a zombie Lego. We used many materials including cardboard, sonotube, foam (styrofoam, insulation and memory foam) duct tape, gorilla glue, hand saws, sandpaper, spray paint, acrylic paint and about 50 hours of work. This is a costume you really want to take your time on. It's totally worth it in the end with all of the pictures and contests you could win!!

How to:
1. Figure out dimensions. This is a lot easier said than done. It took us a few hours. We used graph paper and looked at a normal Lego characters dimensions (you can find these online).

2. Go shopping. We bought everything (for the most part) at Menards. We checked Michaels and Home Depot and they had nothing. Michaels foam is insanely expensive and Home Depot didn't even have white duct tape. So Menards was our best choice!
We bought 12" sonotube for our heads, 8 inch sonotube for the rounded front part of the Lego, we bought 2, 8 feet by 4 feet sheets of styrofoam (1.5 inch thick) for the legs, and top/bottom of the head, 1, 8 feet by 4 feet sheet of insulation foam for our hands and my helmet, spray paint, screen door repair mesh, duct tape (white and black), gorilla glue (2 18 oz. bottles) and large boxes of cardboard. We also went to Walgreens for poster board (white, glossy).

3. Draw out the dimensions on the foam and cut with a hand saw. Once they're all drawn out and cut, glue them together with gorilla glue. A little goes a long way, you will need something heavy to keep them secure. Or clamps. After the glue has dried (2-3 hours) duct tape to keep extra secure.

4. Draw out the dimensions on the cardboard for the body, cut with a handsaw and duct tape together. Make sure you have a spot for your head and arms.

5. For the head, we cut it with a hand saw to our dimensions. We then cut out a circle piece of foam (a little larger than 12") and pushed the sonotube on top of it so it would leave an indentation. We lined the indentation and carved a little out. We then glued it onto the head and after it was dry we sanded it down to get the rounded Lego effect (top and bottom but the bottom/neck will need a circle for your head to go in and out).

6. For the rounded part we cut the 8 inch sonotube the long way so it was a half circle. We then glued and taped it to the bottom of our cardboard.

7. The legs were covered in cardboard and white, glossy poster board and the body, head and helmet were covered with white, glossy poster board and secured with white duct tape.

8. Making the hands we used the insulation foam. We cut up large 10" by 10" squares (4 of them at 1.5 inches thick each). We gorilla glued them, let them dry and then carved out the hands with a hand saw and used sandpaper to make them smooth. We then cut a hole with a hand saw where our hands should go and used cardboard (just rounded it) for our "wrists."

9. Last but certainly not least, paint. We used glossy spray paint for our legs, the back of our bodies, head and acrylic paint for the details! Make sure to take your time on this since it's very important. Also, for the mouth we used a screen door repair fabric. Thin enough so people couldn't see you but you could see out!!!

10. Final details included buying memory foam pads for a twin mattress (target) and cutting it up to go inside of the legs so we could walk with the boots on and inside our hands so they didn't fall off.

Enjoy!!! And good luck.