My son is really into Club Penguin so he requested we make a Homemade Disney’s Club Penguin Secret Agent Costume (search it on the web, Club Penguin Secret Agent Pictures). That is why we have the sunglasses above the beak and the severely modified sport jacket. The body is a piece of ½” foam the covers head to toe. The challenge was the shape of the oval triangle.
The shape made me have to cut out a huge triangle from the back of the coat and fill it back in wit pieces I got from shortening the arms. The feet are slabs of ½ foam with felt covering them. These slip on and off just above the ankle the cover his shoes.
The shirt is white fabric, glued and formed into the collar, and shirt. The body is covered in spray glue, covered in felt then ironed to smooth the material. The head size, and beak matched perfectly to my sons head so he could see out the mouth quite well. The beak is held up by a wire hanger under the foam. This project required a surprising amount of safety pins as out industrial stapler could not reach certain areas of critical connections.