Last year I planned on sharing a tutorial to make the most important part of our boys’ LEGO Legends of Chima costumes – the body. This part of the DIY costume process proved to be the most enjoyable and most expensive of all the pieces to their Legends of Chima costumes. After researching various LEGO costume projects by other fellow DIYers and bloggers, who used cardboard and duct tape, I thought it wouldn’t give our boys much warmth in the cool fall weather, nor stand up well against the rain. And wouldn’t you know, it rained during trick-or-treating event last year.
Thus, I chose to work with foam.
Foam is not cheap, even when you use the 50% coupon at Jo-Anns. I had to make sure I got the cut right the first time. So if you’re looking for some longevity in your Legends of Chima LEGO costume, you’ve come to the right place.
Coordinating colored thread
X-ACTO knife or utility blade
For Laval’s Body:
Royal blue felt
Light blue felt/other light blue fabric of your choice
Navy blue felt or other fabric
For Leonidas’ Body, you’ll need some additional colored fabric:
Step 1. Make the LEGO body template.
Using cardboard, cut out the dimensions of your LEGO body. You’ll need to make at least three templates (1. front and back piece, 2. side piece with arm hole cut outs, and 3. the top with neck hole cut out). Make sure there is enough room for your child’s head and arms to get in and out.
Step 2. Mark and cut body pieces (five pieces total). The front and back piece will be cut exactly to size from your template. For the sides, give an extra one inch beyond the markings. Note: For the side pieces, make sure you cut outside of the marked lines. (I made the mistake of cutting along the line, so I had to shorten the body frame from the sides to attach the pieces together.) Check out Step 4. to see why I recommend adding an extra inch on the sides.
Step 3. For the side pieces, carefully cut into the marked lines to make a fold over the one inch edging. Note: Don’t cut all the way through the foam.
Step 4. Using the one inch overlay as a stabilizing corner, begin sewing pieces together.
Step 5. Using your top piece template, mark your top piece and add a one inch overlay all the way around. (See photo below.) Using an X-ACTO knife or utility blade, you’ll make the same half-way cut along the seams. Fold the overlay snugly into place. Hand stitch top piece into the frame of the LEGO body.
Your green foam body should be complete by this point.
Step 6. Using the same template, mark and cut your colored fabric to cover over the foam body.
For Laval, use royal blue felt. For Leonidas, use an almond colored felt fabric.
Step 7. Sew details to front of LEGO body.
Use an image of Laval to design your details. Below, you’ll see that I used navy blue to make an X-shape with a hexagonal shape at the middle of the X.
Leonidas’ design was a one-strap look across the body.
I added muscle lines to give Leonidas’ LEGO Body a more authentic look.
I also made two kilts to match with a gold belt piece.
Using your front template piece, you can draw up your version with paper and pen. This was my favorite part about the entire project!
Note that the easiest way to give your front a symmetrical look is to divide your paper in half, design your pieces, and cut it to size.
After stitching the front of your design, stitch colored pieces together.
Step 8. To sew the holes, I decided to cut the edges in half inch increments, so that it would fit nicely around the holes. I also cut additional one inch strips and stitched that on the right side out, so that it would cover over the edging.
Step 9. After you’ve sewn all your pieces together, fit it over the foam body. Then hand stitch neck and arm holes into place. Oh and don’t forget that you can hand stitch or use hemming tape to finish off the bottom of the body.
Step 10. Voila! Project complete!
If you’ve made this costume, please let me know how it turned out. I love to see how others have made it into their own.
And thanks to a new reader who asked me to share this tutorial. I never thought someone would be interested in this; so hopefully, it inspires you. (BTW, I’ve made the hat, but it’s not pretty. It was the most stressful part about making the costume, since I’m not a seamstress. If you’re on a budget or on a time crunch, I recommend making a mask instead. I think it would be much easier and more fun to create.)
You can catch up on all the other LEGO Legends of Chima tutorials to complete your little one’s look for Halloween.
From my hometown to yours,