3 Year Old Buzz Lightyear

Hello all. Long time lurker, first time thread starter-er. I recently started my first pep build for my sons halloween costume of Buzz Lightyear. I got the pep files here http://www.therpf.com/f24/buzz-lightyear-pep-files-135200/. Big thanks to EyeofSauron and pepmaster. I will be doing the chest the regular fiberglass and bondo way, and the arm and leg armour will be done in foam.

Starting first coats of bondo

I had to removed the back jet-pack portion of the chest after my brilliant idea of filling it with expanding foam went bad. I will be re-pepping that then fiberglass it before I re-attach it to the suit.

Here's the first coat of filler primer

I wanted to do a test fit on my son to make sure the measurements still held up, but unfortunately his shoulders were to wide to fit through the bottom, so I had to cut it in half.

Luckily everything seems to fit properly and I'll be re-attaching the two halves with magnets and a bracket system. Later added some more beauty coats to try and get everything as smooth as possible.

The plan is to finish the suit with flashing lights where the normal buttons on the suit are, and I'm hoping I can make some sort of system to have the wings pop-out with the press of a button. I will be foregoing the dome part of the costume as I feel it wouldn't add much, and would be to much of a hassle to try and find that. I hope to have more updates soonish.


Thanks for looking.

Looking good so far,cant wait to see final work.

Love it! Can't wait to see it finished. It's going to be great

Thanks for the encouragement guys. Means a lot.
Got a little more work done last night. The front half is pretty close to being done with. I'm hoping to be able to finish both halves this weekend, because I'm really getting tired of sanding. :unsure

Looks great, keep up the good work. I am looking forward to seeing the rest of the project, please keep posting progress and updated pictures as you get them.

Thanks for the support Cooter. The costume is coming along slowly but surely. Up to this point I've finished and reattached the jet pack, hinged the two halfs together, and drilled out the holes for the buttons. I'm going to me molding and casting my own buttons with some resin. Since I'm running out of time all the "buttons" will just light up and blink, instead of having any voice command features.




Trying on the chest piece.


Still have to do some smoothing out around the chest piece, but it's almost ready for paint. Hopefully I'll have some more progress pictures up soon.
Thanks for looking.

Keep it up man. Props to you for making it for you kid

Here are the final pictures of the costume. I didn't have time to take as much progress pictures as I'd have liked to. All and all it turned out alright. The paint job was rushed, and it really shows unfortunately, and then the arm laser LED burned out, and I didn't have enough time to get another one. But my son did have a good time, and that was the most important part.









Thanks for looking. If anything else it was a great learning experience.

Well done your son looked stoked and the over all out come was impressive

It's pretty killer man! Your son will appreciate the hard work in the future when he see's these photos.

Thanks for the comments guys. They're making me feel a lot better about his costume. Here's a video of his lights in action.
Costume lighting test - YouTube
If anything, he was certainly the brightest kid trick-or-treating.