Kyle Pasciutti Design

Q. Is the costume for sale? As this question represents the majority of the over 100 emails I get every time Halloween rolls around... lol

The costume is currently NOT 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 email 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 email 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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