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.