Brady Gage of Monkey 5 Studios is seriously into costuming. His website lists his many projects, and they include everything from Bumblebee to a Batmobile to Muppets. Warning: it’s easy to lose a lot of time looking through all of his work. I was especially fascinated by the Muppet costumes he’s built because he’s made Animal, Miss Piggy, the Swedish Chef, Beaker, and Bunsen. The costumes all appear to be top notch. He uses materials such as foam, felt, bargain clothes, craft foam, and craft fur. He’s clearly resourceful.
The heads seem to all be built the same way: foam. He stacks and glues sheets of foam together to make a block and then carves out the head shapes by hand. He hollows the insides out and carves the face and adds details. For example, the Swedish Chef’s lips are pipe insulation. The foam is ultimately covered with felt.
Here are some more finished costume and work in progress photos:
See many more pictures by clicking on the links at Monkey 5 Studio’s project page.