7.5 ft Tall Buzz Lightyear Halloween Costume

This 7.5 ft Tall Buzz Lightyear Halloween costume took many hours to make but with determination it is quite feasible.  Materials you will need include: papier-mache, EVA foam (home depot), pleather white fabric and vinyl green (both at JoAnns fabric), platform shoes, a chest protector such as motocross or lacrosse, and lots of duct tape (purple, white, and orange).

The backpack is made out of two body board foam board and duct taped with purple duct tape. Cut out a front and back portion using a pepakura (Google pepakura) guide on the internet and glue together to create an outer chest shell.  Typically a hot glue gun works best.  After you let it dry, cut the white pleather fabric to streak evenly and crisp along the Eva foam.  Cut out another strip of Eva foam and cover it with the green vinyl so that it is proportional and placed on the white pleather chest.  Continue this process by making an individual shaped speedo, two thigh and ankles.  After finished, attach the white puse crutches or long boards as a base to develop hands that are proportional to the giant buzz.

With lots of papier-mache begin to sculpt a face proportional to the body.  Make sure to hollow it out so that you can place a bike helmet inside and be able to wear as a mask.  Obviously, everyone will sculpt differently.  The key is to focus on doing your best to making the head as close to resembling Buzz’s as possible.  Be sure to open the mouth as well so that you can easily see! Cut up dowel into joint pieces and create lifelike hands.  Leather and vinyl green where you see fit.

Make sure each piece is removable so that you can move around more easily.  Have fun.  I know it sounds complex, but honestly it is just a lot of repetition and good ole labor!


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    • http://www.facebook.com/juliette.marianocarlson Juliette Lu Mariano-Carlson

      Please explain how you did the lights and the space helmet and the materials used. Thanks!! You have an awesome costume!!

      • Dan

        Thanks!  Which lights are you referring to?  Along the chest is called an EL Wire which you can purchase relatively cheap on amazon.  The rest of the lights are LED or mini flashlights from Big Lots.  The helmet is a 24inch plastic dome that I cut at an angle with a dremel then screwed together.  Hope this helps!


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