Our son is pretty much obsessed with R2D2. So he had to be R2D2 for Halloween. We set about creating a Homemade R2D2 Astromech Droid Costume.
The base was a laundry tube with the bottom cut out of it, with a sheet, sewed into a tube, and then sewed on to the laundry tube to give us a surface to paint. Then a weird colander-like thing was purchased from the local Chinese trading company, and it all started to come together. The legs are made from polystyrene insulating foam cut to shape. The key here was that they had to be spray painted with an HVLP spraygun, since aerosols would eat the foam. Zip ties to hold it all together, free hand pin striping, some electronic lights and we had a versatile costume that pretty much destroyed any other costume we came across. Around 40 hours of work and $100 materials.