Buzz Lightyear & Woody for Halloween (kid size), first time build!

TNTpearson2

New Member
I'm very new to this degree of costume making. My previous costumes consisted of sewing combined with store bought props
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This is what i made last year the night before we needed them. I know the light sabers are the wrong colors but that's all i could find :/

Well this year I've got at better start. I'm making woody the cowboy (almost complete just need to figure out what I'm doing for a hat and make the gun holster from craft foam, something I've never done before). For my 4 year old, I'm making Buzz Lightyear. I've searched and searched for ideas and how to's and stumbled upon this forum. I leaned about foam tiles and how they are awesome for costumes. So my plan is to make the chest thing (sorry new to this, I'm a cake baker/decorator and seamstress not a costume maker) out of foam tiles. I will use a planter to mold them around and cover it with fabric, because i had already bought the fabric before i learned about foam and It'll be cheaper than buying more paint. Im adding a hood to a ready made white long sleeve shirt. making pants and will make a diaper type thing to wear over the pants with the green belt on it. I have foam tubes that will be incased in black to wear around his waist. Im painting rubber boots from last years Luke costume. and making gloves. if i can find a bowl or other plastic the right size I will make a partial dome head thing.

******Since I haven't actually attempted the foam process yet right now what I need help with is lighting???********

I want his "laser" to work but this is NOT even close to my area. I'd be happy with a light that stays on (I've read about the LED taped to a CR2032, i will do that if i can't find another options). It would be even cooler if there was a button to push just like Buzz to activate it. Here's the catch, i don't know how to do it, so i need something i can buy but i don't really know what to search for so I'm coming up empty handed????? I'd also like the wings to have a blinking red and a blinking green (again if they have to stay on they will). I saw someone suggested bike lights so maybe that will work? In the mean time, I am very open to suggestions. I will try to update as I go. Im sure it will be comical for you all to see how I do on my first costume, but I have to start somewhere; its only a matter of time before he asks to be Ironman (his FAVORITE superhero)!!!!
 
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Re: Buzz Lightyear for Halloween (kid size), LED help!

I use any light up toys like finger lights and light up mini swords from dollar store for my costumes. I have some basic knowledge in electronic but you can look up with google.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

yes with the cheapest toys you can find.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

I found some lights that'll do. I've made little progress since the boys kept me busy all weekend and had other sewing projects to do. But husband came home from tx today so I did some work. The boots are painted. I'm going to add glow in the dark paint. Arm template made and the left forearm is nearly complete. I know it's not perfect and my OCD is kicking in with the part of the "hatch" on the bottom left but it'll have to do for now. Tomorrow ill work on the right forearm. Probably try to finish Woodys costume and maybe start the hood.

Oh and the command center logo was a google search image. But I got the idea from this guy.
http://mojoturbocostumes.wikispaces.com/Buzz+Lightyear+Costume

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Sorry I can't upload pics from my phone apparently. Ill try to add them tomorrow.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Here's my photo progress. Maybe my trial and error can help someone else someday.
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Spray painted some knit gloves so the tips would be purple

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Painted black rubber boots white (used plasti dip per other threads on here, i may buy the clear coat to make it glossy) then did purple and green. will go over green with glow in the dark paint.

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Paper template for the arm. will work for right arm in reverse. I just need to remember the cut a seam allowance.

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Mostly done, needs velcro still and you can see the bottom left part of the flap that bugging me where you can see the control panel. oh well.

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here it is on him this morning. you see i didn't have much arm to work with for proportions but he's 4, he doesn't care. to him its awesome!!

I'll get some pics of what i have so far with Woody and hopefully will get some more done today to have more to share.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Buzz parts look great! I really hit a wall last year trying to make Buzz and Jessie for the kids, and ended up making Woody and Jessie. I have photos of how I made Woody's hat, etc - let me know if you would like me to post them.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Thanks!

Azrok, I'd love for some ideas on how to do woody's accesories. I'd hate to spend a ton of time on these costumes to totally fail on the hat.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

I haven't gotten much farther. I spent a couple hours last night working on the right arm and am pretty disappointed with it. the small spy toy i found for a couple bucks is still too big. I am unable to get it apart because it has those darn triangle screws. It was the only one at the store other wise I've considered a hammer :) I'm going to head out to the hobby store and see if I can find some kind of solution. I love that its easy on off with a simple push of a button my 4 year old can operate but i think id rather make a new arm where i could insert an LED and batter taped together that stays on because it would look better. We will see. for now I'm not even going to post a pic because well it was a waste of time. Ill post the ugly one when i have something better to replace it!
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Here's how I did Woody's hat.

Here's my reference photo, from a Google search. Nothing special intended about it being Toy Story 3, I think it was just that TS3 released some good wallpaper photos that helped with reference.
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I started with a cheap basic kids' cowboy hat from uhh, I think Party City? Stroke of luck that it was already brown.
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Removed the white trim and black/white cord.
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Punched holes evenly around the brim. I think I started with a regular handheld/office-style hole puncher, and quickly changed to this hammer/hole punch. Can't remember if that was necessary, but it was easier, and hey it was fun to incorporate pounding something. I think I started at the back, and spaced evenly, so that any off/adjustment in spacing for the last whole would be in the back.
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Bought some brown cord, probably from the Hobby Lobby near work.
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Laced it. The Woody wallpaper photo was helpful for understand how to do the lacing
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Finished!
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Good luck with Buzz costume, you're already miles ahead of how far I got with it. Let me know if need other info on Woody - vest, buttons, shirt, etc.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Thank you so much for the help with the hat. I will check out party city/Halloween city for sure!

I've made progress. I just haven't had time to upload pics and share them, just busy with other orders and kids! Woody is nearly done. Just finishing up the belt buckle and need spurs. Fix the LED laser problem. All I needed was someone to tell me to move on its just a kids Halloween costume. Got the thing apart and put the light back together. I was able to keep the simple push button and got the arm made. Still need to put the light in but it's a lot smaller than it was, so it'll do. I have most of buzz's under shirt done which includes the hood. I want it some what to resemble buzz's armor because we all know a 4 year old may want to take his costume off! I plan to start on the template pieces for buzz today and get
His pants made. Hopefully I can get some pics up soon.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

This is pretty much the completed Woody costume. He still needs a hat and if I have time I will finish the spurs and make a match (Toy Story 1) for his holster. I have the boots but they aren't pictured. The belt and holster are made of felt mostly. Drew the red lines on a ready to wear shirt i picked up at old navy on sale. I painted the shirt buttons yellow to blend in and added large white buttons. It bugged me that they were plain white. I didn't have silver puffy paint so i used blue around the edges and painted it sliver once it dried. I think thats it.

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the belt is too wide to really fit through his belt loops so i used some scraps of denim i had on hand.

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Everything together (minus the boots and hat)

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Buckle close up. its not super clean but it works. I used craft foam and drew the design on it with puffy paint then painted it a dark yellow color. I attached it to the belt with a kam snap.

* Buzz update * undershirt is nearly complete. considering adding black around the waist? pants are done. simple white pants with elastic waist and green added to the bottom. I want to make an "armor underwear" piece. not sure what its called but if you look at buzz you'll get it. not sure if I'm going to use foam or not yet. or even just attach different fabric to the pants…. Time will decided. Template pieces are coming together so i can start work on the main piece this weekend. I'm heading to a party/costume store this week/end and will look for a bowl or something for the visor and woodys hat. time to get cracking on the buzz part….Need this done by the 24th to get it entered in a sewing competition
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Woody also has a pull string on the back I forgot to post a picture of. I'll have to upload that too when I gather some buzz pics. Soon the hard part will be coming where I will need "expert" help. Shaping the foam!
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

I started the foam chest piece for buzz this morning. It's not as bad as I had been expecting (yet). It seems to be turning out well. I've only "formed" the pieces so far. I know some recoil is expected when making a curved piece but I'm wondering how much is normal. Not that I have a lot but I've never done this before and wasn't sure how long to even heat the 1/2" tiles for. I heat them till warm and softish but I can still touch to shape them. So far just trial and error any tips are appreciated. Once I have time to go back out to the garage ill see if they'll be curved enough to glue together.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Finally…Time for some photo updates. Lots done and still lots to go but its starting to come together!

1st attempt at the hood: Blah, i used fleece thinking it will keep him warm if it snows.Decided on the redo to go with cotton lycra
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This was the light toy I had attempted to put in the right arm. way too big
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Horrible
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Got it apart and put together. still not tiny but better!
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And IT WORKS!! :)
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Woody's pull string.
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More pics coming...
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

This is the shirt he will wear under the chest piece, that way when he decides to take it off he still looks like buzz. Its MOSTLY done but I've added more and still needs a few decals ironed on. I just haven't printed them yet.
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Super simple pants. took all of 5 mins to sew up. i don't seem to have a pic with the green i added to the bottom so that will have to wait.
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Swapped out the ribbed cuffs for matching purple cuffs. 2nd attempt at the hood MUCH better. I have added the "ear" pieces and some detail to the bottom waist. still needs that center decal and LIGHTYEAR but I'm waiting to print it with others i need to print
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a few more pics….
 

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Re: Buzz Lightyear for Halloween (kid size), LED help!

This isn't much but its my first time working with foam like this.

I taped the pieces on as the cooled then pieced them altogether. 3 total
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I had a roll of white duct tape and figured why not tape it up? Since i was covering it with fabric anyway...
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Ready to cover it (you can also see the bowl i found that i will cut and use as a partial visor!).
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Finished…For now. and maybe i didn't heat the tiles enough because even with glue and duct tape and fabric one tile is having trouble holding its shape. (wish i had figured that out before i covered it with duct tape and fabric) oh well. And you can see the seams a little (the ones in the pic that you can see are actually the lines of hot glue for the fabric) which i thought would cover better since i wasnt painting it. Next time i will attempt painting. I just didn't want to spend the money since i already had the fabric. hopefully as i add the rest of the details it will help hide all these little things!
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That's it for now.
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Loving the progress on this! My kids would be jealous!

But the pics in the last post aren't working!
 
Re: Buzz Lightyear for Halloween (kid size), LED help!

Thank you! Let me try and add them again….

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Took a few photos this morning of the kids trying on their stuff. Even entered them in a quick contest (Uncompleted!) we shall see how that turns out...
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I'm seeing the chest form pics attached to the latest post but not sure if others can view them? let me know if they're still not working
 

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