Tuesday, November 1, 2011

Buzz lightyear costume for halloween made of UPS and Fedex envelopes

These enveloppes are both really flexible and indestructible, like buzz... So I thought it might give me good results. This is few pictures showing some critical steps in the making of the chest and the wings, I used cardboard and foam for the wings, to give some volume
. The tips of the wings are insulation foam that I painted, same thing around the neck.

The neck, just cardboard I gave a round shape to.
Attaching the enveloppe around the neck using staples.
At this stage, you have to make sure that your child can fit his head through... it's essential!

Almost-done chest before spray painting
Legs, arms and chest.
You might see that I tapes a flat key chain light on one arm, so buzz can still use his laser!

The wings
Wrapping the wings with the envelopes

The other side (each side has a different sponsor....)
To give a great touch to your design, you will have to draw all the space ranger logo on your computer and stick it to the costume with a glue gun.

One of the logo I made....
If you need some of these drawing, drop me a comment and I'll be happy to send you a JPG copy a my drawings.

After doing this project, you'll never look at these envelopes the same way.... Oh and by the way, daddy had fun making it, but his son had a blast wearing it.


  1. I'd love to get some jpgs of Buzz's chestplate and back/wings if possible. I'd like to print them on envelopes for birthday invitations.
    If they're available please email to jlagger03 at hotmail dot com
    thank you!

  2. Can you send me a JPG copy of your Buzz Lightyear. Sea1Pete@yahoo.com
    You did a great job, very nice! Thanks in advance.

  3. SO cute! Great job! I would love a copy of your drawings please! rachiebaby91@yahoo.com

  4. These turned out awesome! I'm gonna try my hand at this too and would love a copy of the drawings. JRBlomberg@yahoo.com

  5. Could you please send me your drawings of all that you made? I am making a Buzz costume for my Grandson for Christmas! Thanks, Bonny Tew

    1. I'll be happy to send the files to you if you give me your email address.

  6. Hi Steph, could you please send me the chest plate drawings you created? They look fantastic!

    Thank you!

  7. Hi
    would you please send me a copy of these drawings .. I'd love to create this for my son's party this weekend. thanks!


  8. Would be great to have drawings of Buzz Lightyear insignia. I am making a costume for a cancer charity event. Many thanks Steve.

  9. Hi, it turned out great! I have a Buzz fan as well. Do you still have the chest plate and wings drawings? Could you email it to: acostapaty@hotmail.com please? Thank you!