Around the time my boys are shuffled off to the school bus for the first time of the year, a catalogue arrives in the mail that elicits giddy anticipation for our favorite diversions of Fall. Halloween costumes! This year, Mom has decided to make the costumes since the boys have chosen more obscure characters — a Minecraft Creeper for the 5 year old and Lego Two Face for my 9 year old.

Two-Face

Two Lego Two-Faces with some sugary henchmen.

How the heck are you going to fabricate those, you ask? Well…I’ve been doing some research on crafting with Fun Foam (also known as craft foam or Foamies), and although it will be challenging for sure, neither of the costumes are impossible to make with the help of Fun Foam (check out the cool costume stuff that can be made).

The Creeper is fairly straight forward and will be my first project. Last night I measured and cut four rectagular pieces for a box body with open ends for the head and feet (yep, that’s right…no such prefab box exists with the right dimensions). Figuring each square pixel would measure 3 square inches, I penned a grid on the outside of the pieces for easy placement of the pieces after the box was fabricated.

The next step was to figure out how to attach the pieces to each other securely enough to withstand the sugar-drunk frolic of an excited first grader hunting for treats. I laid the pieces face down in order and covered them with a rectangle of fine mesh polyester fabric from a remnant I had lying around. Then using diluted school glue, I brushed a coat of glue over the whole thing to bond the box pieces together yet allow them to bend into the box shape.

This morning when I woke up, the piece was warped from the drying glue (of course *rolls eyes*), so my next step is to flatten it again with a heat gun and a piece of plywood before I make a box. Now I need to figure out how to add some kind of suspender straps to make the box wearable.

I’ve looked around for as many shades of green foamies as I could find, but it looks like I’ll have to paint some of the squares. Cutting and gluing the pixel squares will be the most labor intensive portion of the project once I figure out how to complete the wearable structure.

Do you craft? Sew? Knit? Build? Tell us all about what you make for fun. Lurkers especially welcome. As always, Off Topic is welcome as well.

Photo by Chris Christian released under a Creative Commons Share Alike license.