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Coolest Homemade Lego Minifigures Group Costume

This cool LEGO minifigures group costume was inspired by a Lego Chef minifigure found in a local store.

Time Spent

These five Lego Minifigures costumes were created in about 40-50 hours of work.


Materials used were a little more than foam, cardboard and poster board.

Creating our LEGO Minifigures Group Costume

First, detailed measurements were created using a purchased LEGO minifigure. Once the measurements were scaled up proportionately, it was time to start carving foam. In order to create the top and bottom of the LEGO heads, a 2.5 inch foam board was used. Then they were covered with poster board and then painted to a matched color.

Foam legs and mid-section were cut out, faced/backed with cardboard and then coated with colored poster board to achieve the smooth, glossy effect. The bodies were made out of a larger size cardboard box cut to shape and again coated with poster board. Hands were carved out of foam stacked 2″ thick and attached to a section of a cardboard shipping roll and also painted to color.


Men at Work

Lego Group Costume

Coming Together

Lego Group Costume

Lego Group Costume

Lego Group Costume

Personalizing the LEGO Minifigures Costumes

Each person chose their favorite Lego outfit and started drawing and painting the main body. Technology was put to use with the faces. (There was also a LEGO Logo, not pictured, on the back of the bodies). Also, a 1/8 inch thick foam was cut using a laser cutter to achieve the crisp edges.

Lego Group Costume

I can See!

In order to see out of these costumes, each minifigure had to feature an open mouth, which we covered with screen. Overall, this Homemade LEGO Minifigures Group Costume was not very complicated.

In addition, it can easily be recreated to feature additional characters for future years of parties!

Lego Group Costume

Elvis Has Left the Building

Lego Group Costume

Coolest LEGO Chef Minifigure

Lego Group Costume

120 thoughts on “Coolest Homemade Lego Minifigures Group Costume”

  1. The costumes look so much like the real thing. I can not believe they are home made. It looks like you all did a wonderful job! Congrats on a great job! Will you make them for other people to buy????

  2. good job. legos are probably the biggest reason i am who i am. i don’t know if that is good or bad, but the influence they had on me is undeniable.

  3. They were lucky enough to have someone with them that held the doors for them and to hold their drinks. The costumes generated a lot of attention and you can see why…lots of hard work that they should be proud of!

  4. You should think about entering this next yeargis
    on Live with Regis and Kelly!!! They have great
    prizes on there!!! Congrats!!!

  5. I can’t put into words how much you’ve inspired me for next year. I usually stick to the “creepy” costumes, but these…brilliant.

  6. These costumes were SO AWESOME! I saw them at Power Plant Live in Baltimore (where those photos are from) and they blew everyone else out of the water! So cool to see how they were made!

  7. very creative, I really like the simplicity of your overall method to make the costumes. It looks like it cost about as much as a decent made costume. original idea. And because of the almost endless possibilities you will have some interesting designs ahead. look forward to it. great work. 5 out of 5

  8. Johnathan Vrozos is truly impressed by the ingenuity of these 4 guys.
    They took a childhood passion and created a business.
    Well done guys!!!
    I will definitely show my 8 year old to motivate him. He loves LEGO.

  9. These are the the coolest costumes I’ve ever seen anywhere! You guys did an amazing job. My young boys were very impressed also.

  10. Would you consider selling the pattern (measurements, templates, etc)? I would love to make this at home, but would be happy to pay so I wouldn’t have to use CAD to get started. :)

  11. I wish I could make homemade costumes like this. All I can manage at home is a mishaped face mask of sorts and as for the body no way!

  12. Hey! Totally great costumes! Is there any possibility to get more pictures of the making of? I know you have the copyright of it and I doubt it’s gonna be that good, but if you can, please send me some pics and additional instructions to matjaz.sobocanATgmail.com

    thanks in advance!

  13. I don’t know if you guys are still reading the comments but I am currently making the Lego chef costume. Wow what a lot of work! Who knew Lego men didn’t have butts?

  14. I am blown away by these costumes. You guys did a great job!!! I love Legos and I think this will be my costume this year. Hope it turns out just as great!

  15. We also made Lego too!

    Here is our video on how we made our own human size Lego models :)

    Hard work, was stressful in the end…

  16. where can you buy foam like this? I’ve tried a few craft stores&home depot and Walmart but I have no idea where to get foam.

  17. these are better than the costume I had to wear when I worked at Legoland as a costume character. Great Job!

  18. What type of tool did you use to mold the foam?

    Did you use plaster of Paris or something to seal it up to paint the foam sections?

  19. I’ve been scanning the internet for a “how-to” on a minifig costume and this is, by far, THE best I have seen. I can’t tell you how much I would appreciate a pattern or measurements. A list of specific materials and sources would be excellent.

    My 8 year old son would love to look just like you guys did this coming Halloween!

  20. My son really wants to be a Lego character this Halloween. Any chance I could get more detailed instructions? Thanks in advance.

  21. Best versions I’ve ever seen. I truly appreciate the step-by-step pictures. Now my 7 year old wants me to somehow figure out how to scale these down for him. Wish me luck!

  22. WOW, you should sell them I know I would buy one or more for my six yr old. do you give step by step direction on how to build them?

  23. You guys truly out did yourselves! Talk about setting the bar high! But then you shared it too with the rest of us – Thank you so much! I would also love to get more step by step information or measurements. My 9 year old still has his mouth hanging open! I would be very grateful – Thank you Susie at: susieq_03[at]hotmail

  24. I’m going for it I too would love more details and am willing to pay. My boyfriend’s son is a huge Lego fan and I’m sure to gain bonus points if I show up in this costume and more points if I can build him one. Maybe I’ll get him to help build his, he’s very creative for a 7 year old.

  25. After seeing these amazing costumes, I used your example and made them for my two kids. They came out very similar to yours. Took forever, but I had a great time doing it. After much duct tape, glue sticks, poster board, spray paint & Styrofoam later I have the coolest costumes ever. Thank you so much for your awesome pics and directions. I can’t wait for Halloween now, I’m sure my kids will be a huge hit!

  26. amazing, amazing,amazing. just few questions: how were the legging kept on? were there holes in the bottom of the leggings? the middle section , how is it kept on, is it a snug fit? where did u get the Styrofoam at? and how hard was it to go to the restroom with costume on?? :) great job

  27. These need to be made for kids!@ I am having a Lego based birthday party – just before Halloween – how awesome would that be to have the kids be able to dress up in these!

  28. hey guys ,,, your idea,, was wonderful!!
    this Halloween i wanna made this costume … could you help me …!
    explain me …. how did you made it ???


    thxx., for your collaboration !

  29. These are amazing!! Great job! How did you figure out the exact color of yellow and how did you paint the foam? Also, what type of foam did you use?

  30. These costumes are so awesome! My son wanted to be a Lego man this year, but I just thought that it would be too challenging a task because I had 4 homemade costumes to make this year, so we opted for a simpler Perry the Platypus! Now that I see how to make a Lego man, we know what we’ll be next year! I can’t get over how realistic and detailed the costumes are. Truly artistic and creative! As a person who really gets into making homemade costumes and undergoing challenging tasks, I can really appreciate the uniqueness and difficulty of this complex costume. All that work is so worth it! Keep it up! Can’t wait to see your other masterpieces!

  31. I would love to purchase one of these. Its Halloween 2010 today, and would like one for halloween 2011. Could you provide us with an email for contacting you guys? Thank you, Awesome work!

  32. I also made this costume for this Halloween and won 1st place at two locations. It was over $500 total.

    You can view my costume here:

    everyone LOVED this! I can’t thank you enough for this idea. It cost me around $100 and 50 hours to make it. If anyone is interested in buying it, let me know! Just post on the youtube video or email me via my youtube info. Thanks!!

  33. wow …………………………………………………..WOW!……………………………………WOW WOW WOW WOW WOW WoW !……………….I LOVE LEGO!

  34. just wanted to let all of you guys now that your costumes are so awesome!! if gave myself and my boyfriend the motivation to create our own costumes just by working off your models!!

    there is a link!! they came out pretty good!! we won over $2000 for them!!!:)

  35. Ive always loved legos and you guys really brought the enjoyment of playing with a lego to life!!!:) Keep up the good work you guys should do a how to on this project. REALLY COOL!!!:b

  36. i really like doing homemade costumes and you gave me the best idea , so this hallowen mi 4 year old will look like one of your legos. MUCHAS GRACIAS CHICOS EXCELLENTE TRABAJO.

  37. I LOVE it! But logistically speaking, I think my 6-year old son would struggle at school for the day! I’ve made him a Lego Sensei Wu costume that’s a bit simpler…

  38. So my lil guy tells me he wants to be Ninjago Lego “Kai”. I think “OMG – how am I gonna pull this one off?” My job as his mom is to make him the cutest and best Lego ever. Thanks to your awesome photos and details I was able to do just that. He was SOOO EXCITED! We got many compliments. Your own costumes turned out great – I was so impressed! All I can say is thank you, thank you, thank you! Have a great holiday season! :0)

  39. Hi there,

    Do you have any measurements that you could offer on the heads at all or anything else in the costume?



  40. My family and I went to Legoland just last weekend and my son tells me that he wants to be a minifig for Halloween this year. I usually make his costumes, but never anything like this before. I wasn’t sure how I was going pull this off. Luckily I found you!! Great costumes!! Thank you for sharing your ideas. Not sure how to get it scaled appropriately, but hoping to figure it out, got some time yet..

  41. I am thinking of making a lego club max one for my last halloween trick-or-treating expedition!!!!

  42. So I just finished my heads and am sharing the dimensions. The scale is 1/16″ = 2.75″ so when you add faces or legs or whatever–that’s the scale I used. The next piece is a 11″ (diameter) circle with a 9″ hole in the middle for the head. The head base is 16.5″ across and has another 9″ hole in it for the head to fit through. The head top is just a 16.5″ (diameter) circle and the top nob is an 8.25″ circle. The top nob can be used from the left overs of the circles cut out for the head. The entire head with neck and nob–to scale should stand 22″ tall. I used a 4’x8′ sheet of Styrofoam and was able to get 4 heads out of it. I followed the directions as above for the rest. I did realize from their pictures that they either used butcher paper in color or contact paper to cover the boxes and get those really crisp lines. We made 7 so our entire family could go as Legos. Lots of fun and lots of work. Good luck!

  43. awesome stuff. spice it up a bit more and make lego “village people” or the “A-team” or “spice girls”, …

  44. My Husband and I have been wanting to do this for a few years now and these are the best ones we have ever seen. I am going to try it this year and see how it turns out!!

  45. These costumes are amazing!! Love them. But, can you PLEASE tell me how you did the legs and how they stayed on? I’m trying to make a lego minifig costume for my 9 year old son. Thanks so much!!! :)

  46. Amazing! Would love to make one for myself to entertain my daughter, niece, and nephew. Supplies needed? Where can this type of foam be purchased?

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