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Picture of Sully From Monsters Inc

Here's a costume I made for Halloween 2017. It took roughly 150 hours in total and cost $130 in supplies. It stands at roughly 7 feet tall (I'm 6'1").

Step 1: Materials and Tools:

Picture of Materials and Tools:


  • Hockey/football pads
  • Open-cell polyurethane foam (various sizes)
  • Adhesive spray (3M Super77)
  • Glue sticks (~50)
  • Duct tape (1 roll, blue)
  • Old pair of shoes
  • Rigid foam insulation (Foamular 150)
  • 6 yards of blue fur
  • Black & white acrylic paint
  • Gray and light blue vinyl
  • Toy football helmet
  • Black sheer spandex
  • Chicken wire (1 roll)
  • Plastic styrene sheet 12" x 12"
  • 1" PVC tube
  • Masking tape
  • Great Stuff expanding foam
  • Paper mache supplies (newspaper, flour, wood glue)
  • White plastic ladles (2)
  • Velcro (100 inch length)
  • Red & blue food dye
  • Epoxy (optional)
  • Bronze spray paint (optional)


  • Hot glue gun
  • Heat gun
  • Sewing machine
  • Black/Blue Sharpie markers
  • Belt sander
  • Scissors
  • Wire cutters
  • Spray bottle
  • Utility knife
  • Hand file (optional)
  • Hair clippers (optional)
  • Binder clips (optional)
  • Fabric tape measure (optional)
  • Handheld foam cutter (optional)
NoQuartyr1 year ago
Man, that's a "monstrous" endeavor to take on with helping care for a one year old at the same time. Kudos to you! You have my vote! Awesome job man! Just awesome!
jeanniel11 year ago

Booo! You certainly got my vote - an amazing job! LOVE the scales on the tail! You guys must have been a HIT on the block for Halloween!!!

-BALES-1 year ago

Fantastic!! I'm still finding green faux fur in my house from 2 years ago.

macmillj (author)  -BALES-1 year ago


VajkF1 year ago

Instant get!

That is wonderful, great work. Kudos to you!

This is awesome! Both costumes turned out great!

Glumgad1 year ago

It's fantastic! Great job!

seamster1 year ago

This is some excellent work!! Super impressive results! :)

Swansong1 year ago

That looks perfect!!! I love the little Boo running after you too, she looks precious!