It has been a while since I opened that file. The two pieces that both look like eye patterns are two versions of the eye. I should have labeled it. It is a rough version that did not get deleted. 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.

Sully Costume Adult - Etsy New Zealand Sully Costume Adult - Etsy New Zealand

I know I have skipped some steps and will be updated this as I pile up more information. Please comments below and ask any questions on details I might have missed. I will be happy to answer them. Use the PDF as a guide or project the pattern on the wall and trace head pieces onto large sheets of paper 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.

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I started this project with one goal in mind, to create the ultimate Sully costume. I research different techniques that would make him appear more lifelike (think Bear in the Big Blue House) and less mascot (Sparty). While in the suit. Find a good spot for the elbow joint and have someone mark where it should bend. 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. Use the PDF as a guide or project the pattern on the wall and trace pieces onto large sheets of paper Use the body pattern and a starting point. Pin all the paper body patterns to their respective parts.

Sully Costume Adult - Etsy

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. This is a fairly complicated build and I would expect anybody making this on nights and weekends to spend a few months completing the costume.Put Sully on a Mannequin or hang him up somewhere. You want to be able to walk all the way around him. 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. Nine Yards of your 4" pile turquoise gorilla fur should be enough to cover all of Sully. THE FUR IS DIRECTIONAL, MAKE SURE IT IS LAYING THE RIGHT WAY. Watch some basic dress draping videos on youtube. It will give you a better idea how to do it.

Sully Costume - Etsy UK Sully Costume - Etsy UK

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.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. Once you have a rough-in Fur pattern, use some throwaway fabric (I used old bed sheets) to create a rough draft Sully skin. Transfer pattern onto EVA (puzzle Mat) foam. I found my puzzle mat at Five Below, and fortunately was already blue. 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. can't tell you how long I've been looking for a sully costume this well done! I've already begun tracing out everything and gather supplies but was wondering if the "blue flexible PVC" made a difference? All I can seem to find that is blue is furniture grade PVC in 5ft sections or PEX (shark bite)