2016 Halloween Mercury Toddler Costume

Beetroot

Active Member
Hi all,

Here is my take on a budget Mercury Era spacesuit for my son for Halloween this year. First I would like to thank N3rdyboy for his build log

http://www.therpf.com/showthread.php?t=262725

this is what inspired me to give this shot. Also shout outs to Ryan Nagata and Adam Savage who's own Mercury suits served as the primary reference for this build.

So... onto the build. The goal was to replicate the look of suit while still being comfortable for a 2 year old (from experience they have little tolerance for the normal comfort issues found with cosplay) complete this within a couple months for Halloween 2016 and on a budget of less the $50.

Onto the build:

To start with the original concept was to use preexisting clothing to increase comfort without requiring a lot of tailoring.

The Pants:
The pants was the only part of the costume that worked to plan. Take a 3 year old (little bigger so they weren't skin tight) dance leggings (about $5) in silver and add a zip plus a substitute for the "radio connection". The greebly ended up being a part from a toy gun as time was running out. The zip was from a local fabric store which matched the overall aesthetic.
PA312662.JPG

The Top:
This is where things started to fall apart. After trying to find a child's "long sleeve silver top" the best I could find was a men's size. This led to modifications having to be made. After 3 attempts and almost running out of fabric (from the original top) I ended up with a top that fit my son and maintained the overall look. After adding more zips and another greebly, this time scratch built to replicate the valve cover the overall suit was coming together. The final straps and pockets were made using the scraps of the silver fabric reversed, white elastic and grey ribbon with the appropriate width.
PA042647.JPGPA042649.JPGPA062654.JPG
The final step for the suit was the neck ring. The first version made to fit with the helmet was fabricated out of an embroidery ring that could be adjusted. Magnets were added to ensure a better connection with the helmet. This was used for the first round of pictures but was later replaced with a veggie tanned leather strip that was dyed silver.
DSC_0530.JPGDSC_0321.JPG
The change made it a lot more comfortable for my son and still looked pretty convincing. The ring was hot glued on in both cases to allow it to be removed easily. The red fabric was some left over scraps from another project.

All the NASA and name tags were made by printing onto some transfer paper and ironing it onto an old pillowcase with a high thread count, these were then glued onto the suit.

Next will be the helmet...

PA312662.JPG


PA042647.JPG


PA042649.JPG


PA062654.JPG


DSC_0530.JPG


DSC_0321.JPG
 
Last edited by a moderator:
The Shoes:
The original plan was to get some cheap black shoes from Walmart and add the details as required. After starting this I discovered it would be easier to just start from scratch. After using some black vinyl that was dyed silver using some leather dye, and making my own template the 2 parts were sewn together. After this a leather sole was cut to shape and hot glued to the rest of the shoe. after adding the 72 eyelets and some blue zips (happened to be lying around) which were again dyed silver the shape came together. An old flipflop was cut to shape and hot glued to the base of the shoe and the white cord threaded through the eyelets.
_DSC4070.JPG
After a little bit of weathering I decided to add a little tag showing it as government issue, no one would see this but I couldn't resist.
P9152534.JPGP9152535.JPG
The best part of this is that it was almost completely free by utilizing scraps (and those old flip flops) that I had lying around. All I had to purchase was the white cord as my first attempt at using the innards of some parachute cord didn't look right (see above).
 
The Helmet:
This was the most expensive part with the base helmet coming from Ebay for $15.

base helmet.jpg
As a start it was ok once the stickers were removed but the shape was a little off. After a cut was made the shape was slightly adjusted but had to resort to some cheap tricks to cover the cut.
Some foam was painted silver and added to helmet build the rim of the visor.
IMG_2083.JPG
For the interior I had some muslin laying around and some upholstery foam. This combined gave a reasonable replica of the interior.
IMG_2086.JPG
Finally the radio/microphones were made from some scrap black ABS available heat formed over some wood that had been cut to the shape. Some old wires and circuit boards were hot glued onto the interior of the formed plastic in case somebody wanted a closer look.https://www.youtube.com/watch?v=Jgb7MEwcebU
IMG_2084.JPGIMG_2085.JPG
If you want a few more details feel free to check out my video on the matter. Excuse the rough nature of the video I am still working on the process.
https://www.youtube.com/watch?v=Jgb7MEwcebU
 
The Final Costume:
Before the costume got destroyed while Trick or Treating I had the opportunity to take some final photos of the whole suit together.
DSC_0500.JPG14883451_1666389820319473_6912210248714622663_o.jpg14900533_1666389816986140_5247026155638885664_n.jpg
 

Attachments

  • DSC_0541.JPG
    DSC_0541.JPG
    554.7 KB · Views: 132
  • DSC_0551.JPG
    DSC_0551.JPG
    577.4 KB · Views: 121
This is great!!! I want to make an accurate Apollo suit for my two-year-old daughter eventually. I think it would be hilarious. Her head is huge so the helmet would be proportionally gigantic.
 
Thanks everyone, this started off as a last minute project and turned out to be one of my favourite costumes this year. It ended up getting quite a bit of use.
_DSC5230.JPG

This is great!!! I want to make an accurate Apollo suit for my two-year-old daughter eventually. I think it would be hilarious. Her head is huge so the helmet would be proportionally gigantic.
That would be awesome, keep in mind 2 years don't love the idea of helmets. A lot of candy was used in getting these photos. Hahaha!!! Made for a nice candy bucket though.
 
Back
Top