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I started this project with one goal in mind, to create the ultimate Sully costume. I research different techniques that would make him appear more lifelike (think Bear in the Big Blue House) and less mascot (Sparty).

It boiled down to mobility. Mobility would bring this costume to life.

I am going to attempt to break down every step of this costume.

A good amount of time was spent just creating the patterns. Fortunately for anybody making this costume, I completed that task for you.

This is a fairly complicated build and I would expect anybody making this on nights and weekends to spend a few months completing the costume.

Please don't attempt anything that you do not feel comfortable with. watch some foam cutting technique videos. How to use contact cement videos etc.

Please ask questions if something is unclear

Step 1: Supplies

Picture of Supplies
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Shannon Fabric long pile gorilla fur Turquoise - 9 Yards

5 gallon bucket

blue flexible PVC - 8 feet

Gorilla tape - 1 roll at least

Extra tough scrap fabric - 1 yard

Loctite professional strength super glue

Loctite Professional Strength spray adhesive

Puzzle matt EVA foam - at lease a six pack

flex seal white - 1 can

costume claws - I found mine at big lots but you can find something similar

2" upholstery foam - over 9 yards

2" gray pipe insulation - 6 foot

2 smaller buckets - I got mine from family dollar

60 lbs test spider line

little eyelet screws - 18 count

4 inch clear acrylic globe for eyes

Eyeonme2113 days ago
I met this guy who does project like you and he charging me $1800 but I rather pay you because I really like how yo work ..
Please let me know if is possible if not no worries ..
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nbehling (author)  Eyeonme2112 days ago
That is an awesome model. I appreciate the offer but I don't do commissions. I just give away the patterns so other people can make them. $1800 is a fair price. I think you should go with your guy and good luck. It looks like a fun project
TysonR109 months ago
I have been looking for a Sully costume for a couple years and I am excited that I found your build here. This is exactly what I'm looking to do. Thanks so much for sharing this awesome creation. I have got my supplies and I started tracing the patterns on paper. I got the projection set to the right scale with 12" and 24 " markings. What scale did you use for the legs and head?
nbehling (author)  TysonR108 months ago
I'm so excited that you are finding it useful. The head and the legs are all based off the 12" and 24" scale. I would set my projecter to the right scale then just scroll around as I needed to trace different pieces. I hope that's helpful
TysonR10 nbehling8 months ago
Thanks for being so willing share your project and help the rest of us out. I'm sure I'll have more questions along the way.
ReymundoA111 months ago

awesome job! One question on the PDF, what is that second piece, the one that matches for eyes, used for?

nbehling (author)  ReymundoA111 months ago

First off, Thanks for the kind words. It means a lot.

It has been a while since I opened that file. The two pieces that both look like eye patterns are two versions of the eye. I should have labeled it. It is a rough version that did not get deleted.

While we are on the subject. Here is a helpful tip. The top of skull and eyes do not actually touch. Their is a "vent" ridge along the back of his eye. Once the fur is on, you will not see the gap but it will help dramatically with cooling the person inside.

takenjpp1 year ago

Thanks for posting this Sully costume design. It's an amazing engineering design. It has inspired me to create one for my kids. I'm having one problem. The shoulders do they connect to the back, top of neck or do the shoulders remain free from the body of Sully so that they can move? Thanks again.

nbehling (author)  takenjpp1 year ago

The shoulders are connected in two spots with large elastic straps. One on top and one on the back. I will try to find a screenshot for you

Ok, thank you !

Solrius1 year ago

amazing, thanks. a question, what guide you use for the hand?

nbehling (author)  Solrius1 year ago

I made a super simple hand extender using buckets from the dollar store. I cut the bottom off so my hand could go through. Then cut another bucket into strips for the fingers. I screwed the "fingers" on to the "hand" and added eyelets for the line to run through. The plastic did not have to be strong because it was reinforced when it was glued to the foam hand. Maybe this terrible drawing will help explain what I mean.

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the mechanism inside

nbehling (author)  Solrius1 year ago

Hey, I appreciate the compliment. Are you talking about the foam finger part, or the mechanism inside that moves his hand?

Tarantula31 year ago

Too good, thumbs up

nbehling (author)  Tarantula31 year ago

Thank you!

Glumgad1 year ago

Sully is great, Boo is cute

nbehling (author)  Glumgad1 year ago

Thank you. I will be posting my Mike/Boo instructable soon.

NomadMik1 year ago

Amazing work!

nbehling (author)  NomadMik1 year ago

Thanks, Your scarecrow is pretty rad as well!

Dutch561 year ago

Great Instructable! You got my vote! YouTube has a lot of options for making mechanical hand extenders, which one did you go with?

nbehling (author) made it! Dutch561 year ago

Thanks for the kind words and the vote! I made a super simple hand extender using buckets from the dollar store. I cut the bottom off so my hand could go through. Then cut another bucket into strips for the fingers. I screwed the "fingers" on to the "hand" and added eyelets for the line to run through. The plastic did not have to be strong because it was reinforced when it was glued to the foam hand. Maybe this terrible drawing will help explain what i mean

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Thanks for the drawing. I can actually make sense out of it. The hand looks simple to make and has the desired effect.
nbehling (author)  Dutch561 year ago

Really simple, each one took about an hour once I had all the parts

seamster1 year ago

Oh my. This is so good!!

nbehling (author)  seamster1 year ago

Thank you! I just checked out your stuff. you're extremely talented.