I made one for my son like 10 years ago. Earlier that summer I'd snatched this huge roll of pinkish carpet foam that somebody had set out for the garbage men, and I'd brought it back to the shop for a rainy day. :lol
One day I asked Nic what he wanted to be for Halloween, and he blurted out "GODZILLA!" For a minute or so, I was like "Ohh! uhh... Hmmm..." :eek
Then I remembered the roll of foam.
For the head, I measured Nic's head, which by a happy coincidence, was the same diameter as a coffee can, so I had a ready armature to start on. I wrapped some of the foam around the can and hot glued the seam for a neck. then I stacked more of the foam up to block out the top of the head and the face. Then I VERY carefully attacked it with my dremel on high speed and a coarse sanding drum until it was the right shape. I made a couple resin eyes and sculpted the upper and lower inner mouth inserts, made Ultracal molds and made latex copies.
I built up the ridges on the head and back of the neck by just cutting them out of more of the foam sheet and tacking them on with superglue.
Once everything was attached, I mixed up a batch of latex with dark grey acrylic paint and stippled the heck out of the whole head to seal everything together.
Then it got really masochistic-
I took one of his old Power Ranger one piece costumes and proceeded to cover it with
thousands of little foam "french fries" that I cut out of the foam sheeting, soaked in latex and stuck on. (Hehe, there was sharp spike in the electric bill from the hairdryer that month! :lol)
Once I got the body covered and had built up Godzilla's paunch and shoulders, I took one of those big, cylindrical foam pool toys, covered it with thousands more foam french fries, for the tail, then glue it to the butt of the main suit with a lot of latex and let it cure overnight.
For the hands, I couldn't get the boy to sit still long enough for a hand cast, so I made two clay Godzilla hands, checked the size against his hands, then
dipped them in latex. When that was cured, I pulled them off, letting them go inside out, and poof! two Godzilla hands complete w/ texture!
By the time I got to the feet, I was getting pretty burned out, so I just sculpted one toenail, made a plaster mold and cast 8 copies. The feet were more stacked foam, with a cavity cut in the middle layers for his feet. For the soles, I just poured a couple big puddles of latex on a sheet of diamond textured ceiling light plastic, let it cure, then cut out the soles and glued them to the bottom of the feet w/ more latex.
The finished suit weighed close to 40 lbs and he had trouble walking any great distance in it, but boy did he learn to whip that tail around! Within 30 seconds of suiting up, he swung his butt around and "THWACK!" one of the cats flew a couple feet, then half ran, half stumbled from the room! :lol
-Sarge