This project started as an idea for a Halloween costume, transformed into an art project that I (believe it or not) got college credit for, mutated into a commissioned costume for a party interested in having the best Ghostbusters themed Halloween shindig ever, and is finally ending it's run (for now at least) on here as a set of designs for fan to utilize & create their own costumes. The costume has been featured on both GBNews.com as well as ProtonCharging.com, and has generated more than a hundred e-mails from parties interested in purchasing one of their own. Much more information about the costume can be found in the F.A.Q. at the bottom of this page.
.jpg "The Stay Puft Marshmallow Man Costume Designs Full Spread")
Full Spread
.jpg "The Stay Puft Marshmallow Man Costume Designs Upper Spread")
Upper Spread
.jpg "The Stay Puft Marshmallow Man Costume Designs Lower Spread")
Lower Spread
.jpg "The Stay Puft Marshmallow Man Costume Designs Body Detail")
Body Design Detail
.jpg "The Stay Puft Marshmallow Man Costume Designs Leg Detail")
Leg Design Detail
.jpg "The Stay Puft Marshmallow Man Costume Designs Head Detail")
Head Detail
.jpg "The Stay Puft Marshmallow Man First Costume Standard Front View")
Standard Front View
.jpg "The Stay Puft Marshmallow Man First Costume Close Head View")
Close Head View
.jpg "The Stay Puft Marshmallow Man First Costume Low Perspective View")
Low Perspective View
.jpg "The Stay Puft Marshmallow Man First Costume Close Walking View")
Close "Walking" View
.jpg "The Stay Puft Marshmallow Man First Costume Standard Walking View")
Standard "Walking" View
.jpg "The Stay Puft Marshmallow Man First Costume Photo Shoot Picture #1")
Photo Shoot Picture #1
(Go to this photo on
Nafis Azad's Flickr Page)
.jpg "The Stay Puft Marshmallow Man First Costume Photo Shoot Picture #2")
Photo Shoot Picture #2
(Go to this photo on
Nafis Azad's Flickr Page)
.jpg "The Stay Puft Marshmallow Man Costume 3D Head Initial Design")
Initial Design
.jpg "The Stay Puft Marshmallow Man Costume 3D Head Designs Angled View")
Angled View
.jpg "The Stay Puft Marshmallow Man Costume 3D Head Designs Front View")
Front View
.jpg "The Stay Puft Marshmallow Man Costume 3D Head Designs Bottom Opening")
Bottom Opening
.jpg "The Stay Puft Marshmallow Man Costume 3D Head Hat Design")
Hat Design
.jpg "The Stay Puft Marshmallow Man Costume Compressed Foam Arrives")
Compressed Foam Arrives
.jpg "The Stay Puft Marshmallow Man Costume Opened Foam Expands")
Opened Foam Expands
.jpg "The Stay Puft Marshmallow Man Costume Foam Cut and Ready For Paint")
Foam Cut & Ready For Paint
.jpg "The Stay Puft Marshmallow Man Costume Head Initial Clay Modeling")
Initial Modeling
.jpg "The Stay Puft Marshmallow Man Costume Head Old Vs. New")
Old Vs. New
.jpg "The Stay Puft Marshmallow Man Costume Completed Clay Head Model Front View")
Completed Model Front View
.jpg "The Stay Puft Marshmallow Man Costume Completed Clay Head Model Side View")
Completed Model Side View
.jpg "The Stay Puft Marshmallow Man Costume Completed Clay Head Model Petroleum Jelly and Metal Dividers")
Petroleum Jelly & Metal Dividers
.jpg "The Stay Puft Marshmallow Man Costume Completed Clay Head Model Plaster Casting")
Plaster Casting
.jpg "The Stay Puft Marshmallow Man Costume Head Latex and Muslin")
Latex & Muslin
.jpg "The Stay Puft Marshmallow Man Costume Head Foam Padding")
Foam Padding
.jpg "The Stay Puft Marshmallow Man Costume Head Mold Worked Well, But Latex Had Problems")
Mold Worked Well, But Latex Had Problems
.jpg "The Stay Puft Marshmallow Man Costume Painting The Mask")
Painting The Mask
.jpg "The Stay Puft Marshmallow Man Costume Completed Mask")
Completed Mask
.jpg "The Stay Puft Marshmallow Man Costume Completed and Ready For Delivery")
Completed & Ready For Delivery
.jpg "The Stay Puft Marshmallow Man Costume Happy Customer")
Happy Customer!
.jpg "The Stay Puft Marshmallow Man Costume D.I.Y. Designs Foam Cutout Patterns")
Foam Cutout Patterns
.jpg "The Stay Puft Marshmallow Man Costume D.I.Y. Designs Head Dimensions")
Head Dimensions
Q. Is the costume for sale?
As this question represents the nearly 100 e-mails I get every time Halloween rolls around... lol
The costume is NOT currently for sale. I tried making and selling a few, but the time involved in hand stitching each individual costume makes it incredibly hard to keep costs down.
Q. What is the costume made out of?
The body was constructed from Polyurethane Foam sheeting in both 1" and 1/2" thickness available at most fabric and craft stores, though since Hurricane Katrina, it appears to only be shipping in the green colored version. The white material you are probably looking for can be easily found online and usually ships for around $75. The original head was carved out of a solid 1' X 1' polyurethane foam cylinder while the newer head was cast latex & foam. The foam cylinder can probably be found online, but the casting method is completely up to you.
Please Note: I find that polyurethane foam is a great material to work with, but if you do use it to make a costume, please be careful as it is highly flammable when untreated. http://en.wikipedia.org/wiki/polyurethane#health_and_safety
Q. How much did the costume cost to make?
The materials cost somewhere between $100 & $150. The real expense in the project however, lies in the time it takes to hand stitch the whole thing together.
Q. How long did the costume take to make?
I estimate somewhere around the 100 hour mark, though I have yet to actually time the whole process out. If time is money, then you can see where the true value in the costume lies...
Q. Is the costume to scale?
Roughly speaking... Yes. As some of the pictures above show, I used printed images from the movie in order to figure out the scaled sizes of the pieces for the costume.
Q. Any tips on making my own?
Yep! Just like sewing clothes, you will want to sew everything inside out then reverse it. That way from the outside only a seam will be seen, not the actual stitching. Also, the foam has a tendency to turn yellowish brown with age & exposure to sunlight. I recommend keeping the costume in a dark place when not in use. The color change can be stopped completely with a thin coating of latex paint over the surface, but if done incorrectly, this can cause the foam to become brittle. I recommend wetting the foam before painting to help in this process.
Q. Can I E-Mail you to ask a question, or just say that your costume is awesome?
ABSOLUTELY! I love hearing from everyone... Please make sure though, that if you are going to e-mail me a question, that it is not already covered in this F.A.Q. If you think I've missed something, or have other specific questions, don't hesitate... I'm not going to hold your hand while you make your own, but I do love to share..! Please please please, if you are using my designs to make your own costume, I want to hear from you! I'd especially love to see pictures!!!
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