Harry Potter has transformed from a wizard into a LEGO minifig. This costume was made by Instructables user craineum for his son, and he also made a Ninjago minifig costume. The boys requested the costumes for last year’s Halloween, and while they look great, craineum said they were a little heavy for the boys to wear. He has a lot of helpful points in his tutorial but also takes the time to discuss what didn’t work.
Once he took measurements and came up with a 32:1 ratio, he started from the ground up. He made the template from plywood and transferred that to plastic:
I then clamped down the template to the plastic. The thing I didn’t take into account is that going around the corners would create rounded corners when cut with the Dremel. So I ended up using a bit of blocking around the toes and heal of the template to fix this.
After that I cut all the facing pieces. To do the curve I used a heat gun to make it pliable. The hardest part to bend are the edges, so maybe cut these a little long then trim the ends (which I should have done in hindsight). The plastic will want to bend away from the heat, and I would just go with that. That way the hotter and more pliable side will stretch more. The better way to do it is to find something the same size that you can wrap the pliable piece around.
To glue it I cut blocks of wood to the right width then clamped the two sides of the legs to them. Then I would glue the forward facing pieces to the sides and put heavy-ish items to hold them in place. To save the costume from wear as the kids walk I made a horseshoe and glued it to the bottom of the leg.
The head was made from rings of styrofoam that craineum carved into shape. He did a great job smoothing and painting them and getting the hair right.
Read more about the project at Instructables.