Learn how to create my eye-catching and budget-friendly DIY LEGO costumes with step-by-step instructions and creative tips in this fun and informative guide all for under $30!
Last year, after returning home from Europe the pressure was on to figure out what we were going to dress up as for our friends annual Halloween party. I created a list of 25 DIY Couples Costumes for Halloween and shared it with Jon. We narrowed it down and that’s when he decided we were gonna create DIY Lego Costumes. Jon knew if we were gonna do this we were gonna do it right. We scoured the internet and never found a complete tutorial nor could we find real life measurements. So Jon got to sketching while I tried to narrow down which LEGO I wanted to be!
These costumes took us over 40 hours to create and we spent roughly $30! Some would argue go spend the $100+ on buying a costume, but we had fun making them and it was also a race against the clock since we had one week to complete them! By far these were the coolest costumes we’ve ever created in our life! Oh, and did I mention that we might have just taken not one but two categories last year–Best Couples Costume and Funniest.
These costumes were over 7 feet tall and we looked through the mouth portion since where the eyes were was too tall for both of us! We also had a very difficult time getting into our friends house. We couldn’t go through their haunted house because we would have ripped it down and/or knocked something over and getting into their house we practically had to un-assemble our costumes.
Table of contents
- Supplies
- How to Build the LEGO Body
- How to Make LEGO Feet
- DIY LEGO Costume Head
- How to Make LEGO Hands for Costume
- How to Make Foam Maracas
- How to make a Paper Grass Hula Skirt
- Try on the LEGO Costume
- Add the LEGO Logo
- Hula LEGO Costume
- Mean Face LEGO Costume
- Tips & Tricks
- Love all things LEGO?
- How to Make a LEGO Costume
Here is the sketch up Jon created. He scaled down the sizes for both himself “J” and myself “K”. He’s 5’11 and I’m 5’1 so that is what the sizes are scaled too. Here is a rough list of supplies we used for our costumes.
Supplies
- Cardboard
- Foam
- Yard Stick Ruler
- Black Gaffers Tape
- Gorilla Glue
- Hot Glue
- Hand Saw
- Weights
- Poster Tube
- Meat Carving Knife
- Yellow Paint
- Yellow Poster Board
- White Poster Board
- Black Sharpie
- Black Paint
- Blue Paint
- Pink Paint
- Metal Mesh
- White Spray Paint
How to Build the LEGO Body
First, create the base and body of the LEGO costume. Cut out cardboard for the body. Size will vary depending on the person wearing the costume. Secure the carboard body together with black gaffers tape — its super sticky.
Next, we used hot glue and secured white poster board to the bodies and feet. We wanted a smooth surface and found this was the easiest way to achieve the smooth surface.
We wanted a smooth surface and found this was the easiest way to achieve the smooth surface. You’ll noticed plastic in the background. Jon originally thought he was going to spray the costumes with our paint sprayer, but it didn’t work out.
Then, hand paint all the poster board–majority will be yellow and depending on LEGO design will depend on colors you use.
How to Make LEGO Feet
Next, build out the feet. Build the sides of the feet out of thick foam and the fronts and backs out of cardboard. Once the feet were secured and glue was dried we used hot glue and secured white poster board to the feet. We painted the feet the same time we painted the bodies.
DIY LEGO Costume Head
To make the LEGO heads you will want to start by making the tops of the heads. We used heavy styrofoam for the tops of the head. You will need one larger piece and 3 smaller per LEGO costume.
We secured the smaller foam tops on the larger and then painted them yellow and black where appropriate for mine and all yellow for the classic LEGO. Jon used 2-inch strips of cardboard to hold up the tops.
NOTE: Make sure you get all of your cutting done first before painting. Trust me… the last thing you want is foam dust on your freshly painted costume.
Spray paint the screens white that you will need for the mouths. This needs to be done prior to placing on the heads! You will want to also pre-cut the mouths out before placing the poster board on the heads. Once the screens are dry adhere screens to the mouth.
Next, it’s time to secure the yellow poster board on to the lego heads using hot glue. Make sure to place the seams in the back. Then, you will need to either freehand draw the faces on using a pencil OR you can cut faces and apply vinyl to the cardboard.
He penciled on the faces and then began painting. Jon used a black sharpie marker to draw the thinner details including the lines for the hair.
How to Make LEGO Hands for Costume
Next, carve out the hands. The hands were created by layering multiple pieces of foam together with the thicker purple foam. We placed weights on top of the glued together foam over night to ensure that they stuck together. Check out the picture above to reference the layers of foam we glued together prior to cutting out the hands.
We cut “c’s” out of the hands and then began cutting the holes where we would put our actual hands through. We used a large cardboard tube as our guide to cut the holes out for the hands. You will want to use Gorilla Glue to secure the foam together.
How to Make Foam Maracas
Glue a few pieces of leftover foam together, freehand drew the maracas on to the foam. Carved out as much as possible of the foam using the electric carving knife.
If you have access to a drill press, add a sanding pad to it and begin to run the foam around the edge of the sanding pads to get them to be as round as possible.
How to make a Paper Grass Hula Skirt
While my husband worked on the details of the faces I made my grass hula skirt out of a few pieces of green poster board from the dollar store. I believe 3 to be exact. I cut the skirt fringes 1-inch a part and left a few inches on the top.
Try on the LEGO Costume
Once my costume was complete I tried it on sans the feet. It looked awesome and fit well although to be honest–cardboard is not the most comfortable thing to wear!
This was the aftermath! Paper and scraps everywhere… we had just a little bit of time to spare until we had to get to our friends party!
Add the LEGO Logo
Last minute, like 20 minutes before leaving for our friends party we realized we needed to add the LEGO logo to the back of our costumes. So we printed out the largest logo we could find, measured to make sure it was centered and glued them on!
Hula LEGO Costume
And the final product.
EPIC! I loved my Hula LEGO Costume.
Mean Face LEGO Costume
Jon’s mean face LEGO costume was a hit.
All of our friends were amazed and no one could tell who was inside the costumes. It took us 20+ minutes to get dressed into our costumes. Had we had extra time we could have done a test run. This photo was taken at the end of the night and at that point we decided to remove our feet. All of our final photos were taken by Christy Buonomo Photography. She also has a pretty cool blog where she mainly shares Halloween tutorials and other artsy photos she’s done, head on over and check out here blog Through My Looking Glass.
I loved how my costume turned out including my maracas. Even though everyone thought I was carrying around chicken drumsticks! I loved how my skirt actually moved!
I dyed a white long sleeve shirt from Walmart with Yellow dye. It blended in perfect to the costume! Best of all I was able to wear it after Halloween!
And Jon’s costume was super scary because of that face! Our friend set up a photo booth like we were in jail. It was so difficult for us to get under the tent to take photos!
Here is both of us sans feet crammed into the tent with our trophies on our shoulders!
I leave you with scary LEGO face. I’m not sure if it was the face or the fact that the costume was over 7 foot tall that made it scary. On Halloween night as we passed out candy to the kids Jon dressed up in his LEGO costume and stood at the foot of the driveway. He made kids SCREAM… and cry. And some may have thrown their princess wands on the ground and ran away. Who would have thought a 7 foot tall LEGO that came to life would scare so many kids! Even the smarty-pants teenagers were screaming like little girls. It was hilarious to say the least.
I can honestly say, I don’t think we will ever make costumes that out top these ones. They were a labor of love and came out amazing! If you have any questions feel free to leave them in the comments below or email us.
Tips & Tricks
Here are all the tips and tricks we have when making a LEGO costume.
- Boxes – To keep the cost down of the costume trying looking at your local grocery store or whole sale club for free boxes. If not, you can always buy boxes, but the cost of the costume will go up.
- Cutting Foam – We found using a meat carving knife was easiest to cut the foam!
- Weigh Down the Foam – Use weights to weigh down the top of the glued together foam over night to ensure that they stuck together.
- Paint – We used acrylic paints we had at home. We painted the poster board yellow for the heads and part of the body. Spray paint isn’t a good option as it can streak and is hard to maintain a perfect stream of paint. If you can find yellow poster-board you can purchase it already colored–just know it might be more expensive. Depending on your design you will need to paint on the face, clothing, and any accessories.
- Cutting – Make sure you get all of your cutting done first before painting. Trust me… the last thing you want is foam dust on your freshly painted costume.
- Sharpie Marker – We found a black sharpie marker worked perfectly to draw the thinner details including the lines for the hair.
Love all things LEGO?
Since making these costumes and having kids we have shared our love for LEGO’s with them! If your planning a trip to Florida and want to learn all about LEGOLAND you can find more here:
If you make a DIY LEGO Costume, I would be honored and love for you to take the time to leave a star rating and comment! I spend hours developing and testing these projects, and always love to hear feedback and user experience!
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How to Make a LEGO Costume
DIY Lego Costumes
Learn how to create my eye-catching and budget-friendly DIY LEGO costumes with step-by-step instructions and creative tips in this fun and informative guide all for under $30!
Materials
- Cardboard
- Foam
- Black Gaffers Tape
- Gorilla Glue
- Hot Glue
- Poster Tube
- Yellow Paint
- Yellow Poster Board
- White Poster Board
- Black Sharpie
- Black Paint
- Blue Paint
- Pink Paint
- White Spray Paint
Tools
- Yard Stick Ruler
- Hand Saw
- Weights
- Meat Carving Knife
- Metal Mesh
- Hot Glue Gun
Instructions
How to Build the LEGO Body
- First, create the base and body of the LEGO costume. Cut out cardboard for the body. Size will vary depending on the person wearing the costume. Secure the cardboard body together with black gaffers tape -- its super sticky.
- Next, we used hot glue and secured white poster board to the bodies and feet. We wanted a smooth surface and found this was the easiest way to achieve the smooth surface.
- Then, hand paint all the poster board--majority will be yellow and depending on LEGO design will depend on colors you use.
- Print out a LEGO logo to adhere to the back of the costume.
How to Build LEGO Feet
- Next, build out the feet. Build the sides of the feet out of thick foam and the fronts and backs out of cardboard. Once the feet were
secured and glue was dried we used hot glue and secured white poster board to the feet. We painted the feet the same time we painted the bodies.
DIY LEGO Costume Head
- To make the LEGO heads you will want to start by making the tops of the heads. We used heavy styrofoam for the tops of the head. You will need one larger piece and 3 smaller per LEGO costume.
- We secured the smaller foam tops on the larger and then painted them yellow and black where appropriate for mine and all yellow for the classic LEGO. Jon used 2-inch strips of cardboard to hold up the tops.
- Spray paint the screens white that you will need for the mouths. This needs to be done prior to placing on the heads! You will want to also pre-cut the mouths out before placing the poster board on the heads. Once the screens are dry adhere screens to the mouth.
- Next, it’s time to secure the yellow poster board on to the lego heads using hot glue. Make sure to place the seams in the back. Then, you will need to either freehand draw the faces on using a pencil OR you can cut faces and apply vinyl to the cardboard.
- Feel free to pencil on the faces and then began painting. Jon used a black sharpie marker to draw the thinner details including the lines for the hair.
How to Make LEGO Hands for Costume
- Next, carve out the hands. The hands were created by layering
multiple pieces of foam together with the thicker purple foam. We
placed weights on top of the glued together foam over night to ensure
that they stuck together. Check out the picture above to reference the
layers of foam we glued together prior to cutting out the hands. - We cut “c’s” out of the hands and then began cutting the holes where we would put our actual hands through. We used a large cardboard tube as our guide to cut the holes out for the hands. You will want to use Gorilla Glue to secure the foam together.
How to make a Paper Grass Hula Skirt
- While my husband worked on the details of the faces I made my grass hula skirt out of a few pieces of green poster board from the dollar store. I believe 3 to be exact. I cut the skirt fringes 1-inch a part and left a few inches on the top.
How to make Foam Maracas
- Glue a few pieces of leftover foam together, freehand drew the maracas on to the foam. Carved out as much as possible of the foam using the electric carving knife.
- If you have access to a drill press, add a sanding pad to it and begin to run the foam around the edge of the sanding pads to get them to be as round as possible.
Notes
- Boxes - To keep the cost down of the costume trying looking at your local grocery store or whole sale club for free boxes. If not, you can always buy boxes, but the cost of the costume will go up.
- Cutting Foam - We found using a meat carving knife was easiest to cut the foam!
- Weigh Down the Foam - Use weights to weigh down the top of the glued together foam over night to ensure that they stuck together.
- Paint - We used acrylic paints we had at home. We painted the poster board yellow for the heads and part of the body. Spray paint isn't a good option as it can streak and is hard to maintain a perfect stream of paint. If you can find yellow poster-board you can purchase it already colored--just know it might be more expensive. Depending on your design you will need to paint on the face, clothing, and any accessories.
- Cutting - Make sure you get all of your cutting done first before painting. Trust me… the last thing you want is foam dust on your freshly painted costume.
- Sharpie Marker - We found a black sharpie marker worked perfectly to draw the thinner details including the lines for the hair.
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Comments & Reviews
Andrea says
This is, quite possibly, the COOLEST costume ever!! WOW. I am totally amazed by you guys. You’re awesome!
Katie says
Thank you so much Andrea and thanks for having us at your handmade costume party!!!
Rachel @ R & R Workshop says
Wow! I love these costumes!! Way to go!
I’m a new follower 🙂
Rachel @ R & R Workshop
Katie says
Thanks Rachel!
Max says
So awesome! And I’m laughing so hard that it made children cry! I mean it’s LEGO! aha
Katie says
Thanks!
Linda Lee Steaples says
WOW, this is by far the coolest costumes I have EVERY seen. Most definitely a GREAT LABOR OF LOVE !!!!!
SUPERIOR JOB, WELL DONE !!!!!!!! In my book you WON the best of the best awards for every category there has ever been….. Thanks for sharing!!!!! 😀
I Pinned it to my board and I am sharing on all social networking sites!!!!!!!
Katie says
Thank you so much Linda! I still can’t believe we made these costumes!
gail says
I think I would be scared of that face too! 🙂 Knowing jon is really so kind-hearted… the face doesn’t suit him at all. That’s a lot of work guys, but you really knocked it out of the park!
great costumes!
did you keep ’em?
gail
Katie says
haha thanks Gail! He loved scaring the neighborhood kids! Yes, we did keep them… we’ve talked up revamping the outfits at a later date! lol.
Laura / The Shed by Pet Scribbles says
Best DIY costumes EVER!!!! Love!!!
Katie says
Thanks Laura!!!!
Malia says
I just love these. You two are so creative and I love the sense of fun and joy that these costumes convey! xo
Mallie says
EPIC. That is all 🙂
Katie says
Thanks Mallie–we think so, too!
Bonnie @ Uncommon Designs says
Ok you guys are adorable and those costumes rock!
Katie says
Thanks Bonnie!
Sharlyn says
These are sooooooo cool, I’m a little afraid to show my son, he will want me to build one for him! Awesome job!
Katie says
ha ha thanks Sharlyn!
Sara says
Hi,
Awesome costumes! Where did you purchase your foam, and what kind of foam is it?
thanks
Katie says
Hi Sara–sorry for the delayed response. We bought one sheet of foam from The Home Depot. 2″ insulation foam and then we used the high density foam (purple) to help support the hands.
Felt With Love Designs says
Hi! We LOVE Legos in our house, I can’t let my husband see this or he will try to convince me to make one for our whole family!! Love the costumes so much! We included your lego costumes in a round-up we did on no-sew costume ideas! Thank you for sharing!
http://www.feltwithlovedesigns.com/2013/10/04/links-with-love-no-sew-diy-halloween-costume-ideas/
Katie says
Thank you! They were so much work and totally were worth all of it!
Amy says
I absolutely love these. I DID make the mistake of showing my 6 year old son and now he wants to be a Lego guy for Halloween.
I have a question for you… How did you figure out the measurements and how do you get the legs on?? Oh yeah and the “arms” that went into the “C” styrofoam… Is that poster board too? I think I might try and make one for him… Maybe myself too while I’m at it 🙂
amy says
I absolutely love these! I DID make the mistake of showing my 6 year old son and now……. I’m making a lego man costume!!
I have a couple questions for you though. 🙂
How did you figure the measurements?
How do you get the legs on? Did they fit well, or did they move around a bit? Did you have to glue them together once your legs were in them? lol
Great Job! Thank you!!!
Katie says
Thanks Amy–we sent you an email in hopes to answer some of your questions!
Janel says
OMG! These are awesome! My son loves Lego and wants me to make him a Lego costume. I found your site through pinterest and might use your guide to help me make one!
Any thoughts to help make it smaller? He is 4. Also, how do the feet stay on? Do the hands go inside of the ‘c’? Also, is it easy to paint the foam? I would think it would absorb it.
This is amazing!
Thanks
Katie says
Hi Janel,
You would need to scale down the size based on his height. If you look at our photo (sketches of the lego) you’ll see the size we made ours and then scale down from their. We zip tied the legs on to us… not ideal for a 4 year old… maybe forgo the legs? Yes, your hands go inside the “c”. We used an acrylic paint, so it doesn’t eat the foam. Let us know if you have any other questions. Have a great day and thanks for stopping by!
Janel says
Thank you so much for answering my questions! I am going to try to work on this this weekend. We don’t need it until March, but I want to make sure I have enough time to get it done. I’m excited! He is going to love it!
Mark Urso-Cale says
Hi there
Really, really love this, these are great. One question, how did you shape the curve for the top and bottom of the head and smooth off the edges of all the polystyrene/styrfoam? I’ve been able to cut the discs to shape for the head, but really struggling to get the curve to really make the head look good.
Also, with the legs/feet, how did they stay on? I notice you said you took them off so wondeing if you actualy wore them like very big shoes.
Many thanks,
Mark, Oxfordshire, England
Jon says
Hey Mark, Sorry it took so long to reply but a new baby makes everything take longer to do. As far as smoothing out the edges I used my orbital sander with a high grit and quickly and softly ran over the edge to give that smooth appearance. If I had more time on the build I probably would of used and old pair of shoes and fixed them into the big boots because they were flopping around to much making it hard to walk. Or since they go so high up on the leg you could probably put some velcro strap through the sides to strap around your leg leaving the actual big boot roughly an inch or so off the ground. Hope this helps, please send some pics when your done.
Jon
amy says
hi! these are amazing!! thank you soooo much for the tutorial! we are going to be a lego family this year, and the wagon (for hauling my preschoolers) is going to be a lego bucket. thank you for the inspiration and the practical advice! i was worried i couldn’t top last year’s costume, but now I believe i can!
Katie says
Amy glad we could be of assistance. Please send pictures our way! We would love to share with our readers what other readers are building! 🙂
Pat K says
I cannot get a side view of the lego costume for dimensions. Can you please send me the side view dimensions of your lego costume. Thanks.
Katie says
Hi Pat–unfortunately, all we have is that sketch up photo.
shannon says
Hi there! All I can say is… these are AMAZING! I’m totally inspired to do this for my 9 year old. My only questions is how you strapped on the legs? About how long did these take you to complete? And where can I find a big foam sheet like that? Do they sell those at craft stores? Thanks so much for sharing!!!
Katie says
Hi Shannon. Glad we could inspire you. The two costumes took us 40 hours to complete. We used zip ties for the legs… not really ideal for walking around all night. You can find the foam sheet at The Home Depot! Good luck and send us a picture if you decide to make it!
Heather says
Hi there!
Do you have any advice for keeping the legs on/in place? I’m having a hard time figuring out what I could use to help secure the legs so they’re not flopping around all night.
Thanks!
Katie says
Hi Heather, we zip tied the legs to our own legs–NOT PRACTICAL. In hind sight had we had more time we would have added elastic to the inside to wear the legs. Still–a little challenging to walk around with. Hope you figure something out and please feel free to send us photos of your finished costumes! We would love to share with our readers.
Heather says
Hi Katie!
What is the best e-mail to contact you? I would love to send you photos of my costume!
Thanks!
Heather
Pierre-Olivier says
can you please tell me the ”side mesure” we dont see on your picture…. thanks a lot !
Katie says
Hi–sorry I no longer have the costumes nor our scrap piece of paper we scribbled on for the measurements. Good luck!