Our family had a Toy Story theme for Halloween 2007. Our sons were Woody and Buzz (store-bought costumes I’m sad to say) my husband was Zurg and I was Mr. Potato Head.
His costume was time intensive but well worth it. I made the gown with dark purple satin fabric, cut and sewn into a simple rectangle (like a big pillowcase) – holes were left for his head and arms. I wrapped black fabric around his waist for the belt/sash.
His helmet was made with poster board that we spray-painted purple (we couldn’t find purple poster board) and we cut out the mouth section and put yellow construction paper in it for the teeth. We cut out 2 strips of teeth for his eyes. We used an old Viking helmet under the poster board for the horns (and to make it stand up on his head).
The cape is simple black and red satin fabric sewn together.
The breastplate is made from gray vinyl that we cut in a half-moon shape, colored with red markers, and simply wrapped around his neck/shoulders.
The cut is made from black PVC pipe and cardboard. The metallic hose is simply clothes dryer hose and the dial is made from white paper that I colored with crayons. The gloves are gray work gloves that we used extra gray vinyl wrapped around his forearm to form the gauntlets.
This costume turned out so great. It took quite a lot of time (especially creating the gun) but was not too hot to walk around in during an evening in Phoenix.
Total cost: $50
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What a great idea. My son LOVES your costume. Do you want to sell it? He wants it for his dad.
This is great! I really want to go as emperor Zurg for a Disney theme night for a party. How did you make the gun?
My 3 year old wants to be Zurg for Halloween this year! I can’t stomach spending the $100 on a child costume, so I REALLY appreciate this!
Do you still have this costume to sell? I can’t sew a button and I’m having a hard time finding an adult Zurg costume. If you don’t have it anymore, would you be willing to make another? At least the gun/hose and helmet.
what size is it, would you be willing to rent or sell this costume.
I am confused on how you made the helmet from posterboard. Does it have a back to it? did you just tape the front and back together? I would LOVE more detailed instructions on how you did the helmet. Thanks!!! My son is asking to be Zurg and I hadn’t even thought about homemade but with your costume as an example I think I can pull it off. Your amazing! Thanks for sharing!
MomOf3: Send me your email address and I’ll send you more detailed pictures of the helmet. Essentially, it’s 2 pieces of posterboard, spraypainted purple, taped together and placed over the viking helmet.
hello !
thanks for this costumes because it’s a big help for me !! ( I do to deguize me for my job ) and i don’t know make this during two weeks !
I have been looking everywhere for an adult Zurg costume! Have you already sold this? Or would you be willing to make one? Please let me know!
Hello! My grandson´s birthday is coming up and he loves this guy. Will you please send me a step by step of how you made such a nice costume. My email is ingearriaza[at]yahoo[dot]com
Thanks and blessings to all of you.