My Homemade Lego Man Costume was thought up during an academic half day for my subspecialty surgery rotation during my fourth year of medical school. I started with a picture of a scaled Lego man, proportioned my model from that, and made a rough draft on the Weds before it was to be shown. Supplies were obtained Thurs and Fri night, construction began Friday at 8pm.
The main structure is Styrofoam, with a combination of wooden dowels and rubber cement holding it together. The seams and all imperfections were given a coat of drywall putty and sanded. The head was fitted with a 12v fan for cooling, which had the added benefit of a blue LED light to light up the mouth. The arms were made out of a combination of pvc pipe, various other fittings and furnace piping. All parts were covered in vinyl wrap for a glossy finish. The legs are held up by clips and elastic waistband straps. The 2 6 v batteries and legs are held up by a combination of suspenders and a belt.
The finishing touch is a Lego decal embossing the front. Friday night I worked on it from 8 pm until 8 am. I then slept 2 hours and continued to work on it until 7 pm Saturday night, I went to it's debut party Saturday night. A couple of friends from audio obsession helped out at times, and my lovely fiance contributed to Saturday's work. Enjoy.
Two of my friends and I do a local Halloween contest on a dinner / party cruise boat every year. Each year we make our own costumes. So far we have one first place award (for these Homemade Lego Men Halloween Costumes) and two second place awards. We decided on the Legos because we wanted to see if we could pull it off.
The heads were cut from 12" sona tubes with insulation foam at the top and bottom (for the rounded edges). The faces were painted on using a paint marker. The mouths were cut out and backed with black window screen to hide our eyes. The bodies were cut from cardboard leaf containers. The bodies were then covered with colored duck tape and accessories were painted on.
Good luck and have fun!
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