This Homemade Optimus Prime Halloween Costume Idea is based on the “Masterpiece” Optimus Prime Action Figure. There are a few other Prime costumes online, but to my knowledge (based on a number of internet searches), it is the only fully functioning Optimus Prime costume built on drywall stilts.

With my original height of 6’3″ plus the drywall stilts, the helmet, and shoulder exhausts, Prime Stands just over 8 feet tall.

The only pieces not 100% fabricated by me are the helmet (I liked that it came with a voice changer), the stilts (bought at a pawn shop), the gloves (Hockey gloves from a second-hand sporting goods store spray painted metallic blue), and the tires (commandeered from my wife’s gardener cart).

All other pieces are made of cardboard cut to shape with a razor blade and covered with adhesive vinyl (the kind they use to plot vinyl lettering). Some items were spray-painted. Each piece is kept together with either duct tape, vinyl, hot glue, or Velcro.

Rough itemized cost for the whole costume:

Drywall Stilts: $85. They’re a very pawnable item and not hard to find.

Optimus Prime Voice Changer Helmet: $30 on eBay.

Cardboard: Free-ninety-free from neighbors and a local warehouse.

Colored Vinyl: $40 (roughly 20 yards @ $2/yard).

Hockey Gloves: $20 from second-hand sporting goods store.

Spray paint: $6. (Two cans, Yellow and Blue, @ $3 each).

And that’s about all I paid for. All other items were spare parts laying around my garage or stuff I found in junk piles.

Grand total: Roughly $181.00 US (You can cut costs SIGNIFICANTLY just by making the stilts, helmet, and gloves yourself)

I probably spent about 30 hours working on it over the course of the last 6 weeks.

Halloween night was Prime’s maiden voyage. He needs a few adjustments for comfort and maneuverability, but overall I was the hit of the neighborhood. Kids even forgot to ask for candy when they came to our porch. Many parents circled the block and came back to get pictures.

I hope you like it. I’m happy to answer any questions or provide pointers. It was a fun project.

I made my 3-year-old son a much smaller “Bumblebee” costume. I didn’t pay as much attention to detail for him as he’ll outgrow it by Christmas.