Disney and Marvel’s Big Hero 6 introduced us to Baymax. The lovable personal healthcare companion robot is one of the cutest characters of the year (if not ever) but dressing like him isn’t easy. He essentially wears an inflatable suit. Disney has figured it out since the character is available for meet and greets at the park, but cosplayers face a challenge in replicating the look.
Replica Props Forum user victorvulpine started working on a Baymax costume once he saw a trailer for Big Hero 6, and while he’s still figuring out the body (he purchased an inflatable costume), he’s made a lot of progress on Baymax’s head. He used two cheap plastic bowls and a plate from the Dollar Tree to craft it:
This so far has been made from 2 bowls I got from Party Galaxy and used a plate I got from Dollar Tree. I had to take my heat gun and soften the plastic and used a swimming pool filter cover for my mold and pressed formed the plate. So the top of the head would be curved. After that a took some ABS plastic shavings and acetone and made a sludge. that’s bonds very well to most plastics. I glued the plate to the bottom of the bowl and that made the top of his head. There were stair stepping lips on the bowls that I cut off. Then cut off some of the plastic off the bowls on what is the back side of the head. I took out equal amount of plastic off each bowl so the two parts match up. I made more of the ABS sludge and taped the two parts together and added the sludge in the seam on the inside. The sludge take about three to four days to harden.
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