The Lego Movie Emmet Costume

My 7 year old son Alex is wearing the costume. He is obsessed with Lego and decided he wanted to be Emmet from "The Lego Movie" for Halloween. We grabbed a box, covered it with orange Bristol board and added on details with paint and duct tape. For the head, we tried different things - foam rings glued together, bristol board rolled up, but none of those looked realistic enough. We had an extra plastic Lego head sorter that was about the same size we needed for a head so we used that. I cut the insides of the head out, drilled holes for the eyes, and scraped off the old eyebrows and mouth. Then, I added new eyebrows with a Sharpie and cut out the new mouth. Next, I colored a piece of dry wall mesh tape to look like Emmet's mouth. I finished it by adding a red spray painted hat and yellow rubber gloves. My son was the hit of a pre-Halloween event that we went to. The total cost was less than $30. The Lego head was the most expensive part at $20 on sale last Christmas.