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Optimus Prime Costume

by dannyeurena on October 20, 2008

Table of Contents

Optimus Prime Costume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: Optimus Prime Costume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Creating the head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Step 3: The Chest Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 4: Adding comfort and detail to chest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 5: Painting the chest piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Step 6: Chest piece detail and flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 7: Torso coming together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 8: My two left feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Step 9: Creating the legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Step 10: Getting them feet to dance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Step 11: Completing the lower leg & Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Step 12: New Helmet needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 13: Almost finished . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 14: Arms & Side Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Step 15: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Step 16: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Step 17: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

http://www.instructables.com/id/Building-Optimus-Prime/
Intro: Optimus Prime Costume
When first beginning my search for the most AWESOME Halloween costume ever created, I first wanted to pick something I've always loved... this lead to my childhood
amore for Transformers which eventually became my Magnus Opus or Optimus Prime to be exact. Once I had the idea I shared it with my family and thus began the
endless nights, thousands of Glue gun burns and my invasion occupation of my living room. I unshackled the little geek in me and let him run buck wild 'til his heart's
delight.

All together I spent about $40 - $50 bucks, finding most materials from what I had in my garage or around the home.

Things you'll need:

- Hot Glue Gun (and sticks - the bigger the bag the better)
- Duct Tape (Red, Gray)
- Masking Tap (Mainly for paint)
- Small Ruler and Big Ruler
- Exacto Blade
- Scissors
- Spray Paints (Primer, Red, Blue, white and Mettalic)
- $.99 cents store Mini Flashlights (4 of them)
- Hard HAt (about $6.00 at any Hardware Store)
- Velcro (Found at Major stores like Target, Kmart etc.)
- Lots and lots of cardboard, or foam board. Most companies throw out scrap or just go to your local markets and ask them to save you some before tossing.
- 2 tin cans (emptied of course)
- 2 plastic report sheet covers (for the windshields)
- I used old Hockey Gloves but any cheap canvas ones will work.
- Packaging tubes or PVC piping

Over the last month I've found myself staring at piles of trash while driving, hoping to find something I can use for my costume. Always try to be frugal and inventive.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. Key ingredient #1 a good cold drink to keep you refreshed
http://www.instructables.com/id/Building-Optimus-Prime/
Image Notes
1. I almost never used this glue because of the wait time for it to dry. The Hot
Glue Gun by far was my best investment.
2. I started with the Helmet from an old Snow Board helmet, but found it too big
and heavy, so after becoming more skilled at the materials I scrapped it and
replaced it with an improved on you'll see later.
 Image Notes Image Notes
1. Made from Foam board which holds paint great and is easier to cut than 1. After deciding and cutting your pieces always reinforce inner bends with duct
cardboard. tape. You'll need it when you start moving around in it and you start to notice
tears.

Image Notes Image Notes

1. The back and top open up with flaps for easy access. They held in place by 1. You will definitely need to plan ahead by setting up an area where you can
strips of velcro. (Try to sew or hot glue them into place to hold) paint and allow things to dry.

Image Notes
1. Of course Spaceballs is on in the back ground. (remember good TV)

http://www.instructables.com/id/Building-Optimus-Prime/
 2. These are the $.99 mini flashlights I picked up at the 99 cents store. I will add
batteries and use them the night I wear it.
3. I didn't want a plain blue background. I liked how in most posters Optimus
has a reflection of light or clouds on his chest pieces.

Image Notes
1. This actually can slide up into the chest cavity to make it possible for me to sit
or bathroom breaks.
2. I added these windshield wipers just for that special attention I like.
3. This Melon head will be replaced by a smaller helmet later.

Image Notes Image Notes

1. The feet have about 6 foam pieces from an old Kitchen rug stuck together like 1. Boxes don't normally come in Pyramid shape so this took some time to
a stack of pancakes. It makes me 6 to 8 inches taller. measure, cut and paste. Leg length and measurements were carefully taken.
2. This old pair of sneakers is held in place by a strap. The cardboard piece over
it opens up like a flap.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. Strips were created to add texture. The boring part is you have make 4 of
them.

Image Notes
1. The Tin can and wheels were bolted into place after painting so they won't
shear off accidently.
2. The vents are foam board again which is thicker but lighter than cardboard
which makes them easy to glue into place as needed.

Image Notes Image Notes

1. This is the NEW Helmet. Built on a Low end Hardhat. I pulled off the straps 1. You may notice that I pulled these sides off the old helmet and just stuck them
and just added interior padding. It's lighter and smaller which should make the on this new one!
night more comfortable and less exhausting.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. I plan on buying a cheap pair of blue sunglasses (at the 99 cents store again
or some discount mart) to cover the eye space and continue the illusion.
2. You may notice that I did a redo on the arms. For comfort I locked the
shoulders into place, opened the upper arm more and changed the gloves to an
old pair of Hockey mitts.
3. The front of these shoulders are held in by velcro flaps which help putting it Image Notes
on and taking it off. 1. I added these side wheels, made of cardboard to hide my backside a little as
it hanging in to wind.

Image Notes

http://www.instructables.com/id/Building-Optimus-Prime/
 1. You'll notice I added a little more detail. Now that he's complete, he just sits
on my living room floor waiting to save mankind or for the geek in me to reach
nirvana.

Image Notes
1. Who knew that when Optimus removed the mask he was Latino. "Viva
Optimus"

http://www.instructables.com/id/Building-Optimus-Prime/
Step 1: Creating the head
Let start with the head.

First select an old bicycle, snowboarding, or hardhat helmet that you never plan on using again.

From the Cardboard or foamboard

- Cut 2 ear flaps (Triangle shape)
- Cut 1 center unit piece (Retangle Shape)
- Cut 2 side discs where you plan on attaching the 2 antennae. (circle discs) Antennae.

Like most of this project it will be a series of trial and error to make things fit, the ear flaps are no exception. Once you have your desired shapes cut out, you'll need to cut
circles on the inside to affix to the helmet with hot glue. Adjust fast because the glue dries quick.

The Center unit will present the biggest challenge as the concave center will need to be cut out with your best estimate then refitted for additional cuts. Remember don't
over guess because you can always take off more, but you can't regrow once cut. Take your time on this fitting, it will pay off in the end.

Finally as for the side discs, just cut out 4 identical round discs, then for interior spacing take small scraps of cardboard and stack them like pancakes. Identical in number
so both discs are even. Sandwich the small scraps with 2 discs and glue in place. Wrap then glue with out rim with a thin strip that covers the sandwich space. While
drying cut out 2 long strips which will be the antannae (equal length) then measure out there width on the strip part of the disc. Cut slats on the discs just big enough to fit
the antannae then put some glue on the tips and insert in the hold. Attach to the outer flaps and you've got an Optimus helmet.

Prepare for Painting by taping open areas of fabric with masking tape and any plastic bags around the home. Primer first, then paint over with the blue color of your liking.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. I almost never used this glue because of the wait time for it to dry. The Hot Glue
Gun by far was my best investment.
2. I started with the Helmet from an old Snow Board helmet, but found it too big
and heavy, so after becoming more skilled at the materials I scrapped it and
replaced it with an improved on you'll see later.

Step 2:
The Grill was made from Foam board found at any Target, Kmart and many times are at CVS or RiteAid stores. It comes in big sheets of 36" x 24" and is pretty
inexpensive. (You'll maybe need 2 sheets for the entire project, more if you're prone to recuts)

I cut out a cross shape on it about the size of a regular sheet of paper (8" x 11-1/2") then folded and hot glued the edges together. Again the better your measurements
and cuts in the beginning the better your final project will look.

I cut 1 center line the same length as the longest side (11-1/2") and hot glued it to the center.

I then measured and cut out 16 equal slats, slight taller than the interior depth because I planned on slanting them. Carefully I glued each slat into place, visually trying to
adjust them to the same angle slant. (Trust me your hands become more skilled as you do this.)

Luckily foam board doesn't require primer as it is almost alwasys ready for paint.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. Made from Foam board which holds paint great and is easier to cut than cardboard.

Step 3: The Chest Piece

Basically it's trial and error for sizing.

Take a box, slide it over your body like a sock and guess how much needs to be cut to fit perfectly around your chest without counting your arms into the space. Cut out 2
big holes on the sides and try it on again. Most times your guess will be spot and won't need redoing.

Cut a vertical opening in the back so you can enter and exit easily.

Close off the top and cut out a big head hole. (Cut it a little larger than your head so your shoulder/neck muscles will fit through it better. (You may notice that while a box
is perfectly happy to have all 90 degree angles, our shoulders aren't built that way. The have a little bit of a downward "V" shape)

Duct tape all interior bends. This reinforcement will become invaluable as you work the suit and tears begin to reveal themselves.

Image Notes
1. After deciding and cutting your pieces always reinforce inner bends with duct tape. You'll need it when you start moving around in it and you start to notice tears.

Step 4: Adding comfort and detail to chest

The opening on the back has an additional interior overlaping flap that I used to affix velcro straps to. Kinda like putting 1 hand over the other.

I put 2 strips and tried sewing them in for reinforcement but found the needles couldn't hold up so I hot glued them. If you can get any sewing in I recommend it highly as
sometimes the glue tends to rip off the first layer of cardboard.

Here I've added an awning flap where I plan on putting the small flashlights I bought at the 99 cents store.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. The back and top open up with flaps for easy access. They held in place by
strips of velcro. (Try to sew or hot glue them into place to hold)

Step 5: Painting the chest piece

It will become invaluable for you to set up an area outside your home where you will perform all your painting. Not only will it find itself being used all the time, but it's a
good place to allow things to dry while your working on other parts.

Here I've set up the chest piece and small flashlights for paint. (Apple red of course)

Try to save your paint by knowing ahead of time what will be showing and what will be covered by other parts. As you can see i didn't paint the front slats in the chest
piece becuase I knew I would addint windshield pieces later.

Conserving your paint with bring the dollar value on your expenditures down, so don't paint the inside please; that would just be ridiculous.

Image Notes
1. You will definitely need to plan ahead by setting up an area where you can paint and allow things to dry.

http://www.instructables.com/id/Building-Optimus-Prime/
Step 6: Chest piece detail and flare
Once the chest piece paint is dry, I hot glued the flashlights into place and used an extra amount of glue for reinforcement.

*word to the wise, if paint is not completely dry, the hot glue will melt the paint and make the bond weak, meaning a.) You'll have to repaint, and b.) Your glue won't stick.
So wait until it's dry for sure.

I cut out 2 windshield slats to slide into the chest openings then paint them sky blue. The lighting bolts you see were cut out of regular white print paper then Elmers glued
into place. I then took 2 plastic sheets found on those report covers I used to hand in to school, and cut then glued them over the blue sky and lighting bolts. This will give
you that glass reflective look without actually have glass.

Hot glue them into the covering and if you want create an outer frame for them by painting metalic foam board strips and hot glueing them to the outer edges.

As you may also notice I painted the bottom of the fram metalic by masking off the top portion with tape and plastic bags found around the house.

*Side note: Notice Spaceballs is on the TV in the background!

Image Notes
1. Of course Spaceballs is on in the back ground. (remember good TV)
2. These are the $.99 mini flashlights I picked up at the 99 cents store. I will add batteries and use them the night I wear it.
3. I didn't want a plain blue background. I liked how in most posters Optimus has a reflection of light or clouds on his chest pieces.

Step 7: Torso coming together

I spent a lot of time refitting to make sure things work well. I put all 3 parts together.
1-Head
2-Chest
3-Torso

I kept the lower torso separate from the upper chest portion and similar to the chest piece I opened up the back of the lower torso and used velcro as the clasp. Think of it
as a girdle of sorts. adjusting to whatever weight or body types needed. It's pretty much a box that's open on top and bottom. I double walled this torso because I knew it
would have to survive multiple attempts at sitting.

I made it slightly thinner than the upper torso so it could slide into it when I sit down, like an accordion. I also added a pair of suspendors to the inside to help with the
weight and to keep it from sliding down.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. This actually can slide up into the chest cavity to make it possible for me to sit or bathroom breaks.
2. I added these windshield wipers just for that special attention I like.
3. This Melon head will be replaced by a smaller helmet later.

Step 8: My two left feet

To create the feet I took an old pair of shoes and and old industrial floor mat. (Like the ones store cashiers or chefs use) and stacked them on top of each other.

- Decide on how big you want the feet and create the box+trapazoid design you want.
- Cut out 8 to 12 pieces out of the foam and hot glue together on a pancake stack.
- Save just enough foam for the top layer where you will trace out a silouette of the bottom of your sneaker.
- You will cut out that silouette and put the shoe in. This will keep your shoe from sliding back and forth inside.
- Hot glue a velcro strap around all the foam pieces so that it meets just above the shoe. This will hold the shoe down into the silouette and give you more stability.
- Now build the shell around the foot and for added strength, insert some screws into the foam through the cardboard.
- When you paint make sure the shoes aren't inside the boxes!

Image Notes
1. The feet have about 6 foam pieces from an old Kitchen rug stuck together like a
http://www.instructables.com/id/Building-Optimus-Prime/
 stack of pancakes. It makes me 6 to 8 inches taller.
2. This old pair of sneakers is held in place by a strap. The cardboard piece over it
opens up like a flap.

Step 9: Creating the legs

Boxes unfortunately do not come in pyramid form so you'll have to enlist your old Geometry skills for this one. Luckily you can skip the Pythagoreum Theorum on it.

Measure the length of your leg and go about 4 to 5 inches above the knee. Remember you can always cut away more, but your can't regrow cardboard.

Add strength and durability to the pieces by affixing duct tape to the interior bends. Again this will help with tears.

Fit the bottom opening to the feet and cut as needed. Double wall whenever time, energy and cardboard allow. It will help in the long run, but it does make the outfit a little
heavier.

Image Notes
1. Boxes don't normally come in Pyramid shape so this took some time to
measure, cut and paste. Leg length and measurements were carefully taken.

Step 10: Getting them feet to dance

Once you get the right fit for the leg to foot balance, how to do keep everthing from slopping around?

I added velcro strap to the top of the legs that attach just behind the knee. With the lower half hugging the outside of the feet and the top half held against my knee you'll
find it very stable and comfortable.

I also began making the design for the front of the lower leg where the vents will be places.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. Strips were created to add texture. The boring part is you have make 4 of them.

Step 11: Completing the lower leg & Paint

I found an old 4x4 razor scooter in my garage and decided the wheels would make great tires for the side of the legs. You should be able to use an old Big Trike or
broken kids toys to use as wheels. (I don't recommend taking them from a toy that's still being used as this might upset the previous owners)

If you can't find any, and need to create some. Then see step 1 about creating discs. Same procedure different paint.

For Gas Cannisters I used old Tin Cans and painted them the same metalic as the other parts.

*Special note: Bolt these wheels and tin can to the leg piece. Just using glue is not enough. They will be knocked off. Make sure you use washers whenever bolting
anything to cardboard. This will held secure it better by not punching holes in your creation.

Use the same technique for creating front vents that you used for creating the stomach grill. Foamboard works great.

Image Notes
1. The Tin can and wheels were bolted into place after painting so they won't shear off accidently.
2. The vents are foam board again which is thicker but lighter than cardboard which makes them easy to glue into place as needed.
http://www.instructables.com/id/Building-Optimus-Prime/
Step 12: New Helmet needed
After working with and mastering the materials I felt a new Optimus head was needed. The old one was too heavy, too hot and looked like a melon head on top of an
already growing upper torso. I felt like a school mascot. So I scrapped it and re-did it from scrap.

I purchased a HArd Hat at home depot for $7 bucks, pulled off the straps (becuase they raise the helmet off your head too much and hot glued some padding in it, I
ripped off an old bicycle helmet.

the reuslts were much, much better.

I made the sides thinnner and reused the side flaps and antannae from the first helmet. I recommend this one instead of using a snowboard helmet!

The face shield was cut then painted metalic to match the other parts of the costume. It's removable and held in place by 2 small pieces of velcro on the inside. I plan on
purchasing a pair of blue tinted sun glasses to wear underneath as I've already got severe tunnel vision in this helmet and don't need to further reduce my line of sight.

Don't forget... PRIMER THEN PAINT!!! IT'S A MUST!!!

Image Notes Image Notes

1. This is the NEW Helmet. Built on a Low end Hardhat. I pulled off the straps and 1. You may notice that I pulled these sides off the old helmet and just stuck
just added interior padding. It's lighter and smaller which should make the night them on this new one!
more comfortable and less exhausting.

Step 13: Almost finished

Once all the parts were completed I began the comforting process. This means like a wedding dress, I fit then recut and repaste and added duct tape for reinforcement.

The arms are basically 3 boxes.

- The shoulders were originally loose but then I decided the weight was too much and they began to sag (droopy optimus) so I attached them to the chest piece, which
made it difficult to get in and out of, so I made the front of them flaps that open up like garage doors. When not open they're held shut by 2 small pieces of velcro straps
on each interior side. Unless someone undoes them, they hold pretty well. (Hot glue of course)

- The exhaust pipes are from onld packaging material. Fabric stores have these and toss them. The're thicker than toilet rolls and stronger than Bounty roll tubes. I
recommend they be sturdy as I plan on having them tugged at all night long on Halloween. They, like the tires on the legs, are bolted on. Again to prevent shearing. The
holes are painted on using label stickers. I firts painted the lower half black. Waited for it to dry; placed the stickers evenly apart, then painted over them with the metalic
spray paint. after drying I simple peeled off the stickers carefully with a pair of tweezers. You'll notice I shaded the tops to make them appear used.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. I plan on buying a cheap pair of blue sunglasses (at the 99 cents store again or some discount mart) to cover the eye space and continue the illusion.
2. You may notice that I did a redo on the arms. For comfort I locked the shoulders into place, opened the upper arm more and changed the gloves to an old pair of
Hockey mitts.
3. The front of these shoulders are held in by velcro flaps which help putting it on and taking it off.

Step 14: Arms & Side Wheels

You'll notice the side hip wheels were added to hide my backside as I plan on wearing tights Halloween night. Since cardboard is not very breathable, being able to wear
underwear will help me keep the heat off. OF course they are bolted on for strength.

The waist piece is just some rubber foam matting I found at Target for $1.24 in the clearance section. I added the raised yellow pieces by cutting them out and wrapping
them in bright yellow duct tape.

The thigh pieces both open in the back and are free standing. They have overlaping velcro closures and are reinforced by straps I found on an old baby front back pack.
The velcro wasn't enough, as they would open when I tried to sit, so adding these straps was very helpful in keeping them closed. The design is just lines and dots,
although I did add some shading on the outside to make it look more industrial.

As for the Arms, I was lucky that my Garage Junk included a Polycentric Hinge that I used to stabilize the upper and lower arms. See the attached design to help you
visualize how the arms were created. Let me know if you have any more questions on the arms and some of the small details.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. I added these side wheels, made of cardboard to hide my backside a little as it
hanging in to wind.

Step 15:
The final piece was deciding on what gloves to wear. At first I had a canvas pair that were already blue. You might have see them in the background of some of the other
pictures. But ultimately I decided that an old pair of hockey gloves would be best.

They look more robotic, have more padding so the cardboard doesn't dig into your wrist and just fit the overall dimensions of the suit better.

Unfortunately the material does not lend itself to being painted, so I had to apply about 6 coats becuase each one kept being absorbed over and over again until finally it
held. I have no remedy of this, just some advise to make you you save an entire paint can for just this.

http://www.instructables.com/id/Building-Optimus-Prime/
Step 16:
If I look tired in this picture it's because I am. I've lost so much sleep and some nights I didn't even sleep at all. This was last Sunday 10/19/08 where I've been up for
about 36 hours... but I finished it!

Now If only can remember where my bed is. It's been so long that I might have trouble finding it.

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes
1. Who knew that when Optimus removed the mask he was Latino. "Viva Optimus"

Step 17:
Two things you'll need to plan on are:

1.) Your home is going to be an absolute mess. If your wife has problems with little messes, then she's going to freak out and problably going to want a divorce before
this is over. Try and clean up as you go along. It will definitely get knee deep in trash. Also cover any important wood you'll be working on with layers of extra cardboard.
You'll be digging into it with your Xacto knife if you're not careful.

2.) Set an area aside in your home where you can place the completed pieces. Preferably out of foot traffic or where the dog will pee on it. This costume takes up a lot of
space so make sure you don't damage your hard work. Also pre-plan how and where you intend to store the costume once completed. Luckily I have a garage and lots of
packing material. If your single it could become permanent art in your room, but if you have a girlfriend or spouse these things are not possible, as they will clash with the
Pottery Barn theme she is working toward.

All in all I have to say it's been one of the most rewarding expiriences. Lot's of time and love went into it. I hope you can find or commit the same amount when creating
yours. I leave you with 3 bits of advice:

1.) Learn the interior fold for cleaner lines.

2.) Duct tape all bends for reinforcement
3.) Learn to work on 3 to 4 hours of sleep a night.

Godspeed and good luck

http://www.instructables.com/id/Building-Optimus-Prime/
 Image Notes Image Notes
1. Key ingredient #1 a good cold drink to keep you refreshed 1. You'll notice I added a little more detail. Now that he's complete, he just sits on
my living room floor waiting to save mankind or for the geek in me to reach
nirvana.

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Comments
50 comments Add Comment view all 570 comments

tacosmith says: Nov 10, 2009. 9:29 PM REPLY

My three year old wanted to be Optimus prime for halloween so I had to scale the costume down quite a bit. Thanks for the good design Idea!! He loved it
and the family was impressed with what you can do with some cardboard and a bunch of hot glue:)

jtigermask13 says: Nov 11, 2009. 6:24 AM REPLY

Tacosmith, great job, especially since it had to be scaled down tremendously...really awesome.

http://www.instructables.com/id/Building-Optimus-Prime/
 thebeatjackson says: Aug 7, 2010. 11:45 PM REPLY
Thanks for the great instructable!

andy_thai says: Feb 23, 2011. 2:25 PM REPLY

Hi all,

Just so you know, although its 2011 and been 3 yrs since this post,
there is still sum1 attempting this costume and DATS ME!!! Its still
alive!! Its been 2 days into this project and i like what i'm seeing
and the motivational effect is coming through (hope it lasts). Anyway,
in case theres sum1 else attempting this, shout out. I will post pics
and we can all trial and error on the steps we're unsure of. Would love
to hear comments from those who have theirs done. Here are my pics so
far:-

andy_thai says: Mar 19, 2011. 10:21 PM REPLY

I'm finally done!! If had more time, I would add the details for the legs. Still, many were in awe! If you are trying this up! Continue!!! You will be very much
satisfied when you see people's reaction!

http://www.instructables.com/id/Building-Optimus-Prime/
 muscleflex says: Mar 10, 2011. 3:00 AM REPLY
Hi - thanks for posting photos. I have started making this costume too for my 4yr old son. I shall add what i have done so far.

muscleflex says: Mar 2, 2011. 7:49 AM REPLY

the front: (windshield area) is it supposed to be flat or is it kinda wedge shape like the above photo?

andy_thai says: Mar 17, 2011. 11:10 AM REPLY

he got it kinda wedge shape. i made mine flat to avoid tears.

ekongpogi says: Feb 22, 2011. 5:22 PM REPLY

I would like to thank dannyeurena for his work he shared. It gives me an idea on where to start my robotics costume for the competition and it won the 8th
national robotics dance. thanks! here some pictures.

Mr.Sanchez says: Jun 26, 2009. 4:47 AM REPLY

! Que chimba parcero ¡...that means: awesome dude...but in colombian style nic3 to know that latins are just heart and love, and the dance...MAN...seems
like the CUMBIA that we do here...mUY VACANO....

dannyeurena says: Jun 26, 2009. 8:49 AM REPLY

Muchas Gracias amigo! We all are heart and love, and it just goes to show that no matter what your birthplace or skin color, we all dream and choose our
journeys on seperate but parralel paths. Have fun with those kids in your picture, they the next generation of dreamers!

Mr.Sanchez says: Dec 6, 2010. 9:21 AM REPLY

Hi there Would u pls vote for my entry ...?
http://www.instructables.com/id/Homemade-Belt-No-sew/
thnks

http://www.instructables.com/id/Building-Optimus-Prime/
 andrewmystery says: Dec 5, 2010. 3:56 PM REPLY
For the next otakuthon, I'll definetely try to make this! Totally awesome

Hellspawn666 says: Oct 27, 2010. 2:49 AM REPLY

Thanks for this fantastic instructable!!!! I've had a blast, creating this costume for myself ! It's about 90% done and I will post some images soon

Hellspawn666 says: Nov 11, 2010. 3:23 PM REPLY

Here are some pics from the Hal-Con Sci-Fi convention in Halifax, NS, Canada, that I attended. I won 2nd place in the SCI-FI Recreaion - TV category !!!
Thanks again for this wonderful instructable !!!

SnowDogBill says: Nov 3, 2010. 3:21 PM REPLY

Finished in time for Halloween. Not as good as some of you other guys but still a bit hit. Thanks to dannyeurena for paving the way for the rest of us. Also a
HUGE thanks to my wife for putting up with the mess in the living room for so long.

http://www.instructables.com/id/Building-Optimus-Prime/
 alarova says: Oct 31, 2010. 6:12 PM REPLY
I just completed mine, got stopped by so many people in the street. pictures and all. Thanks for great instructables :)

cheechmarin123 says: Oct 31, 2010. 1:56 PM REPLY

Finally finished and thanks to your inspiration I'm now $600 dollars richer. I even got a guy out of a DUI ticket when the cops saw me walk out and ask in a
very transformer way "what seems to be the problem officer. thanks again. here's some pics of my attempt. If i had another week i think i could have
perfected it.

plasticslug says: Oct 27, 2010. 4:10 PM REPLY

I have 2 days, i would be starting from scratch.... can this be done?

http://www.instructables.com/id/Building-Optimus-Prime/
 king kolton9 says: Oct 31, 2010. 6:25 AM REPLY
no

vesgacarlos says: Oct 30, 2010. 2:59 AM REPLY

Thanks!!!!!!

bbkrillin says: Oct 27, 2010. 8:23 PM REPLY

If I had the whole of October to attempt this i would of, sadly there are only four days till Halloween so i doubt i have enough time and resources for such an
amazing project.

But NEXT YEAR it's on!

(btw, i signed up to instructables just to see the full guide to this piece, you sir are a genius)

thisisgregory says: Oct 24, 2010. 7:02 PM REPLY

I'm doing the best I can with what 'art' skill I have. I'm going with original style optimus but going to give him a modern paint job once he's put together.

Keep yall posted!

lockycharmzzz says: Oct 15, 2010. 2:38 PM REPLY

i was looking around on youtube and instructables to get some ideas on how to construct an 80's Jazz Autobot costume when I stumbled upon yours. I have
to say, your costume is among the best Transformers costume I've seen.

krebsisthebest says: Oct 10, 2010. 7:53 AM REPLY

I love any version of Optimus Prime, but old school is the best I.m so glad I found this site and your instructable!! This is my attempt at my own Prime suit.

http://www.instructables.com/id/Building-Optimus-Prime/
 timothycoblentz says: Sep 30, 2010. 3:17 PM REPLY
It's looks Cool!!!! how can I make that kind of this?

bwm3093 says: Sep 28, 2010. 11:44 AM REPLY

hi im having trouble with dimentions, i was wondering what size you are and weather u could send me ur dimentions my email is
benjamin.menahem@yahoo.com

chwbcc says: Oct 30, 2009. 12:34 AM REPLY

Hey I finished a Mini Prime form my son!

It mostly follow your photos, and some of your instructions, I just didn't have time to really give it must attention to detail... After all I started this around 7pm
last night? It took about 6 hours to complete!

I posted some details of the project here:

http://405th.com/forums/index.php?showtopic=22416
I mentioned this project but I will give you better props after a few hours of sleep. My fingers hurt and I am tired but here is a photo of the pieces:

grayrhino says: Sep 16, 2010. 6:06 PM REPLY

do you have instructions for this one? I searched the link you posted but could not find it.

thanks

chwbcc says: Sep 17, 2010. 10:26 PM REPLY

http://www.405th.com/showthread.php/20964-Optimus-Prime-%28Duck-Tape%29-Wip?highlight=optimus+prime

Here is the link to the post, the site it's hosted on crashed and most of the image links were lost so I have posted them below.

http://www.instructables.com/id/Building-Optimus-Prime/
 grayrhino says: Sep 21, 2010. 8:27 AM REPLY
Thanks thats great! did you use velcro to hold the pieces together? And how did the leg pieces stay on?

chwbcc says: Sep 24, 2010. 3:37 AM REPLY

Velcro? Na that is too complicated for me! :lol

I actually used duck tape to hold it on him!

The upper arms were just taped to his shoulders and the abdomin was taped to his chest. The torso was supposed to be taped to his belly but
it worked out better to just attach it to the ab section. The legs had some foam placed loosely on the inside that helped keep them in place but
the only thing that really kept them from falling off was the angle of his leg to this shoes.

Velcro now that would have been a great idea! Because, I did this in about 7 hours the night before Halloween, I didn't put a lot of planning
into it.

The other pieces you see on the suit are toliet tubes for smoke stacks and a tube from christmas wrapping paper for the tires. The windows
are just light blue lightening bolts I created in windows paint. I created one then duplicated it then printed it.

My favorite part is the smoke stacks just because I used small strips of silver tape to hold them on and when I looked at it all night on
halloween they looked like hinges for his arms!

Prime_Villarreal says: Sep 22, 2010. 10:15 PM REPLY

Great work. i would like to see what you all think of mine. thanks

http://www.instructables.com/id/Building-Optimus-Prime/
 bwm3093 says: Oct 14, 2009. 6:54 PM REPLY
Hey, building my optimus and another question came to mind how did youacheieve the bend in the center of the chest peice and im also not clearon how
you made the bottom where it connects to the torso peice.

cochez says: Sep 18, 2010. 1:56 AM REPLY

Its not a bend, from what I can tell that is the cut he mentioned, velcroed to achieve the angle

PuckstoppingPoke says: Oct 14, 2009. 9:51 PM REPLY

With the exception of the pieces around the thighs, I am finished with my Prime.

To danny and all the other posters, thanks so much for the help.

I'm attaching a picture without flash so you can see my lights in the helmet and on top of the cab (chest piece), a regular pic, and also, notice me getting my
Wii Fit on. Actually it is the only thing in the house that could tell me how much the thing weighs.

25.4 lbs of costume, in case you're wondering!

If anyone wants to see other assembly pics, let me know. I have lots of them.

grayrhino says: Sep 16, 2010. 6:09 PM REPLY

would love to see the other pics if you still have them

dannyeurena says: Oct 23, 2009. 11:22 AM REPLY

Justin... you are a stud sir! The light idea is still an awesome one that I hope people will copy to no end. You look like your 8 feet tall!

The gawks and jaw drops you're going to get will be plenty. Kids will run to you, beautiful women will want to take pictures with you and men will be
jealous cause your costume "Kics A***!!!!"

Please post more pics of the back and side so we can behold your work of art!!

Thanks again!!

jtigermask13 says: Oct 20, 2009. 6:38 PM REPLY

OK, I'm now working on the feet, confused...am I stacking the foam onto a cardboard box...in other words, are the bottom of the shoes cardboard or does
the cardboard only surround the shoe...?

http://www.instructables.com/id/Building-Optimus-Prime/
 dannyeurena says: Oct 23, 2009. 11:24 AM REPLY
Cardboard Around the foam. It will help with skidding. Cardboard can be slippery. If the Foam is also slippery then I recommend slip strips or pads.
Women use them on shoes all the time. About $2 bucks.

Good luck! (Post pics!)

blazinmt says: Oct 21, 2009. 8:55 AM REPLY

My cardboard only surrounded the foam. I did however completely cover the bottom of the foam in duct tape before surrounding it with cardboard.

dannyeurena says: Oct 23, 2009. 11:26 AM REPLY

I glued the stacks together and then put some screws in the side to keep it frmo shifting. Duct tape is just as good (and my best friend when
cracks appeared).

Just make sure the bottom isn't made slippery. Last thing you want to do is take a spill after spending so many hours on it!

Thanks Blazinmt.

(Sorry for the delay in my replies, I've been working on this years costume and have had little extra time to reply to anyone... look for my next
Costume Post soon)

jtigermask13 says: Oct 21, 2009. 1:39 PM REPLY

OK, thanks...will be posting pics very soon...thanks again!!!

krebsisthebest says: Sep 7, 2010. 8:40 PM REPLY

Me too, could you post a pic of the inside of the leg? So we can get a better idea of how and where to attach the Velcro straps. Here's my progress so far

ninjanody says: Sep 5, 2010. 11:38 AM REPLY

+ respect... the costume rocks...

ked1997 says: Aug 28, 2010. 6:48 AM REPLY

Does it transform?

aerehthqeth says: Aug 10, 2010. 4:51 PM REPLY

umm i am having trouble walking in my costume especially up stairs do u have any suggestions??

Trooper14 says: Apr 18, 2010. 12:58 PM REPLY

Nice

mc.panzzy says: Apr 14, 2010. 10:54 AM REPLY

cuanto tiempo tardaste en hacer todo el traje??

ktalex says: Mar 19, 2010. 10:25 PM REPLY

i never finished mine hmm maybe this year it could be the year.

view all 570 comments

http://www.instructables.com/id/Building-Optimus-Prime/