This take on everyone’s new favorite Star Wars droid BB-8 isn’t a costume, exactly, but it would make a cool prop to feature alongside a costume from The Force Awakens in photos. When you’re not utilizing as a Rey costume accessory, it makes for awesome home decor. The life-size replica by Instructables user Named Johnny is priced right, too. He crafted his BB-8 from foam for about $100. The small catch: The build includes some 3D printed parts, so if you don’t alreayd have a printer, you’ll have to have them printed elsewhere or you’ll have to improvise.
The basic shapes come from 20 inch and 12 inch styrofoam balls (you might have to order the bigger size online, but the smaller one should be available at local craft stores). Named Johnny sanded the styrofoam before drawing BB-8’s pattern onto it and filling it in. You can see a couple work in progress pics below.
Get the complete tutorial at Instructables.