How to Make a Furry Monsters Inc. Sully Cosplay

Pixar’s Monsters Inc. featured a variety of, well, monsters. The giant furry blue Sully was one of the stars, and Instructables user nbehling set out to make an ultimate costume that was both true to the movie, lifelike, and mobile. After gathering supplies and sketching the frame, nbehling drew a pattern to make Sully’s frame from foam (he shared the PDF on Instructables).

Once he moved onto crafting the shape of the head, he had to make the eyes. He used four inch plastic globes for the base. he says:

Trace the circle onto a piece of EVA foam. Cut out the circle the same size as the globe.

Use a piece of pvc pipe or something similar to punch out the pupil. Use a larger piece of pvc or something round to score a larger circle around the Iris. This gives the eyes some much-needed life under the dome.

Paint the pupil black. Tape off the iris and Plastidip the whites. Take the tape off the iris and use a series of different shade blue sharpie shades to draw in the details. Basically, draw progressively larger triangles till you reach the whites of the eyes.

Glue the pupil back in place. push the foam eye into the globe creating a convex eye. The white plastidip will have enough grip to temporarily hold the eye in place. Once the eye is positioned right, glue it in place.

This video shows off the detailing on the costume:

See the sketch below and view the Sully costume in very early stages.

Learn about the entire how-to process at Instructables.


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