Use the PDF as a guide or project the pattern on the wall and trace head pieces onto large sheets of paper

Use EVA foam for his teeth. Just measure his lip size, cut out the desired teeth length, use a Dremel to carve the teeth as one piece, and glue it behind the lower lip.The bottom of the feet is EVA foam. I don't have an exact pattern. use the size of the legs to guess feet size. I am 6'3", I had to a foam extension on the side of the hips.

Use a piece of pvc pipe or something similar to punch out the pupil. Use a larger piece of pvc or something round to score a larger circle around the Iris. This gives the eyes some much-needed life under the dome.While in the suit. Find a good spot for the elbow joint and have someone mark where it should bend. Spirit Halloween is the largest Halloween retailer in North America, with over 1,450 pop-up locations in strip centers and malls across North America. Celebrating nearly four decades of business, Spirit has cemented its position as the premier destination for all things Halloween. Known to many as an exciting and interactive event for shoppers, Spirit stores offer complete selections of costumes and accessories for infants/toddlers, children, 'tweens, teens, and adults, along with exclusive jaw-dropping animatronics and décor you won't find anywhere else. In fact, Spirit knows how to have so much fun, it's scary! Once you have a rough-in Fur pattern, use some throwaway fabric (I used old bed sheets) to create a rough draft Sully skin. At this point, you should have a blank blue head with a nose and a pretty good idea where you want the mouth. Cut the mouth out a bit smaller vertically that you think. Then use the heat gun to soften the jaw area and pull his mouth more open. Trust me, it looks more natural that just cutting it all out of his face. Look how your jaw changes when you open your mouth and try to emulate that. If you're looking for amazing Monsters Inc costume ideas, just imagine that your goal is to work at the epic power plant of Monstropolis. Think of this as your very first interview to join the team of Monsters Inc. Will you get tossed into the mailroom? It is hardly the illuminating career that you were aiming for, right? Sure, it is important to be part of public service, but you probably imagined joining the police force or becoming a firefighter if you were going to go that route.

Sketch on a smile and where you think the eyes would go. It will make it easier to determine where the bridge of the nose should go. I just eyeballed this step. It is important to create the right arch on the bridge of his nose and freehand the bottom of his nose once the bridge is attached. Use a Dremel tool or a really sharp blade to soften the features of his nose. Monsters are a standard staple when it comes to Halloween havoc. They come in all shapes and sizes, not to mention style! You've got your fuzzy-wuzzies. Those are your werewolves, abominable snowmen, and the classic companion, the bigfoot. (Or would it be bigfeet?) Anyway, then you have the bitey-wighties. That category includes your vampires, brain-eating zombies, and run-of-the-mill creatures known for gnawing. Finally, there are the kooky-spookies, the classy-casties, and the build-a-boos, which close out our classic monsters with the ghosts, witches, and your Frankenstein-style monsters, respectively. But, if you really want to stand out and earn your marks in Monstropolis, you might need to become a monster who isn't so easily categorized! Cut out the pipe insulation for his lower lip. Plastidip and paint the piece a slightly off blue color. glue his lip on from inside the head.The spine is one of the most important parts of the costume and is load bearing. It is worth taking your time to get right. Put Sully on a Mannequin or hang him up somewhere. You want to be able to walk all the way around him. I created a simple hand extender mechanism so I could control his fingers. A simple youtube search will go into a lot more detail on this process. Transfer pattern onto EVA (puzzle Mat) foam. I found my puzzle mat at Five Below, and fortunately was already blue. Well, we’re here to help give you the full tour of Monsters Inc. and Monsters University so you can find the costume of your nightmares (and that’s a good thing). Each of the epic characters from your favorite Pixar films are pretty unique in their own right. Sulley appears to be what happens when cotton candy from the Carnival gets transformed into a huggable brute. Mike is like a Beholder from Dungeons & Dragons if it traded its extra eyes for technical talents. And just wait until you see what happens when the legendary Medusa really lets her inner beauty shine! With so many options, we better get moving. Let’s incorporate some lovable monsters into your costume couture!

wear blue compression gear under the suit. It helps you stay cool and if any part gets exposed it will be the right color.

Wrestle the beast once again and put his fur on. At this point, your ENTIRE house should be covered in blue fur. Sew it all together and wrestle with the beast for a while and make sure it all fits (the fur is not cheap so I would rather make mistakes now.