Lost Hours
New Member
I’ve been lurking on these boards in one fashion or another for a long time. Now I have finally been inspired to start my first costume build, and it is for my son!
My son turns three this month, and when he is not getting excited about Octonauts, Paw Patrol and trains, he is all about the 1980’s Dungeons and Dragons cartoon. Him and his sister, six years old, both have watched the complete series multiple times thanks to the magic of DVD, and his favorite character is, of course, Bobby the Barbarian
I finally hit on the idea of making him a Bobby the Barbarian costume for Halloween (and just general play time) and decided that it was a great project to chronicle here on the RPF.

Here is the plan as it currently stands…
The Helmet
Last night we purchased a How to Train Your Dragon Viking Helmet from Toys’R’Us. This is going to be the basis for Bobby’s horned helmet. 80% of this part is going to be a repaint, silver dome and white horns, just a little weathering. Bobby’s helmet has a spike on top and I’ll add that with a piece of shaped and painted foam. The inside of the helmet will require a small amount of foam to help it sit better, as it currently is just a bit too large. We may possible go for a wig as well, as we just cut his long blond hair a few months back. I’ll have to see how he reacts to it.
The Fur Boots and Fur Briefs
Like the rest of the costume, I plan on keeping it simple. I’m taking a diaper cover that still fits him and will use it to draw out the template. Then I’ll cut some faux fur from the fabric store to shape and attach it to the cover. The elastic in the cover will help it stay on. The boots will be a simple shape attached to an older pair of his sandals. The leather wraps will be faux leather with a small amount of thin cardboard to help them keep the shape.
The Chest Armor and Bracers
Here, we need to keep it simple and comfortable. I am thinking large sheets of brown crafting foam cut to shape and hot glued. This will keep it flexible and he will be able to move in it. Also, and spills will just slide off and not soak in. The metal studs will be plastic balls (think ball pit) cut in half and painted silver. For the bracers, again we go with craft foam shaped and glues to his size. The studs on it will be painted ping pong balls which have been split in half.
The Club
This has been my head scratcher. I want it to be in scale for him, but cannot do an elaborate sculpting and molding at this time. My first thought is couch foams that have been cut and shaped, a layer of white glue to seal them, and then paint and weather. A dowel road down the center would give support.
The other idea is to take cardboard and cut them to shape, forming the body via layers of varying sizes. This would be glued and have a dowel rod or flat bass wood in the center for support. Then either a spray rubber or plastic-dip to give the paint and weathering a base. The big thing with the club is that it needs to be light and soft(ish) for him to carry around and not hurt anyone when he inevitably hits them, but sturdy enough to last through some bashing.
And that’s about it for now. I plan on getting into gear with the actual production this weekend and will post pictures of progress as I can.
Has anyone ever done a Bobby the Barbarian costume? Anyone have suggestions, ideas, or experience that would help me in this? I have a feeling I may end up working on my daughter a costume as well once she realizes I am working on her brother's, but that will be another thread!
Feel free to comment! Thanks all!
My son turns three this month, and when he is not getting excited about Octonauts, Paw Patrol and trains, he is all about the 1980’s Dungeons and Dragons cartoon. Him and his sister, six years old, both have watched the complete series multiple times thanks to the magic of DVD, and his favorite character is, of course, Bobby the Barbarian
I finally hit on the idea of making him a Bobby the Barbarian costume for Halloween (and just general play time) and decided that it was a great project to chronicle here on the RPF.

Here is the plan as it currently stands…
The Helmet
Last night we purchased a How to Train Your Dragon Viking Helmet from Toys’R’Us. This is going to be the basis for Bobby’s horned helmet. 80% of this part is going to be a repaint, silver dome and white horns, just a little weathering. Bobby’s helmet has a spike on top and I’ll add that with a piece of shaped and painted foam. The inside of the helmet will require a small amount of foam to help it sit better, as it currently is just a bit too large. We may possible go for a wig as well, as we just cut his long blond hair a few months back. I’ll have to see how he reacts to it.
The Fur Boots and Fur Briefs
Like the rest of the costume, I plan on keeping it simple. I’m taking a diaper cover that still fits him and will use it to draw out the template. Then I’ll cut some faux fur from the fabric store to shape and attach it to the cover. The elastic in the cover will help it stay on. The boots will be a simple shape attached to an older pair of his sandals. The leather wraps will be faux leather with a small amount of thin cardboard to help them keep the shape.
The Chest Armor and Bracers
Here, we need to keep it simple and comfortable. I am thinking large sheets of brown crafting foam cut to shape and hot glued. This will keep it flexible and he will be able to move in it. Also, and spills will just slide off and not soak in. The metal studs will be plastic balls (think ball pit) cut in half and painted silver. For the bracers, again we go with craft foam shaped and glues to his size. The studs on it will be painted ping pong balls which have been split in half.
The Club
This has been my head scratcher. I want it to be in scale for him, but cannot do an elaborate sculpting and molding at this time. My first thought is couch foams that have been cut and shaped, a layer of white glue to seal them, and then paint and weather. A dowel road down the center would give support.
The other idea is to take cardboard and cut them to shape, forming the body via layers of varying sizes. This would be glued and have a dowel rod or flat bass wood in the center for support. Then either a spray rubber or plastic-dip to give the paint and weathering a base. The big thing with the club is that it needs to be light and soft(ish) for him to carry around and not hurt anyone when he inevitably hits them, but sturdy enough to last through some bashing.
And that’s about it for now. I plan on getting into gear with the actual production this weekend and will post pictures of progress as I can.
Has anyone ever done a Bobby the Barbarian costume? Anyone have suggestions, ideas, or experience that would help me in this? I have a feeling I may end up working on my daughter a costume as well once she realizes I am working on her brother's, but that will be another thread!
Feel free to comment! Thanks all!