How to Make a LEGO Construction Worker Costume

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You don't have to be a Master Builder to master this LEGO Construction Worker Costume. It's instantaneously recognizable, easy to make, and comfortable to wear. You'll be singing "Everything is Awesome" the whole night through -- and mean it!

Things You'll Need

  • Duct tape in light grey, black and white
  • Painter's tape in blue
  • 1/4 inch wide black tape
  • 3/4 inch masking tape
  • Large tuna can
  • Dessert plate
  • Round 12 inch diameter storage basket
  • 3 8x11 inch sheets of yellow craft foam
  • 3 18x24 inch sheets flourescent orange paper
  • Black permanent pen
  • Ball point pen
  • Scissors
  • 24 inch ruler
  • Hot glue gun
  • White glue
  • X-acto knife
  • Square box (14x14 inches cube for a 3 year old sized costume)
  • 2 yellow number 2 pencils
  • 2 cans of Pringles
  • Wax or Parchement Paper
A giant yet tiny LEGO.
A giant yet tiny LEGO. (Image: LEGO Construction Worker)

LEGO Head

Step 1

Take your 12 inch storage basket and cut off the rigid rim.

Shorten your plastic basket.
Shorten your plastic basket. (Image: LEGO Head Step 1)

Step 2

To create the face, remove 3 of the slats (or 3 inches, total, should your basket have tighter slats), from the base, creating an empty space. Tape the sides of the basket up top together so they don't flare out.

Tape the basket so it doesn't flare.
Tape the basket so it doesn't flare. (Image: LEGO Head Step 2)

Step 3

Cover the exterior of the basket in craft foam, leaving it so it hangs two inches over the top and below the bottom of the basket. Tape another piece overlapping so the whole basket is covered in diameter.

Line the outside with yellow foam.
Line the outside with yellow foam. (Image: LEGO Head Step 3)

Step 4

Cut the bottom of the sheet into tapered triangles. Hot glue the triangles to the base of the basket. This will prevent the foam from overlapping and getting lumpy.

Taper foam ends.
Taper foam ends. (Image: LEGO Head Step 4)

Step 5

Using a plate as a template, cut an 8 inch circle out of the foam that is a little smaller than the bottom of the basket.

Cut out a circle.
Cut out a circle. (Image: LEGO Head Step 5)

Step 6

Hot glue the circle over the edges of the foam to cover the bottom of the basket. This will now be the top of the head.

Glue a circle on the top.
Glue a circle on the top. (Image: LEGO Head Step 6)

Step 7

Using an empty tuna can as a template, trace a circle out of yellow foam. Cut it out. Cut two pieces of foam that measure long enough to cover the outside of the can.

Cover tuna can.
Cover tuna can. (Image: LEGO Head Step 7)

Step 8

Hot glue the circular foam to the inside bottom of the can. Glue one strip to the outside of the can and one to the inside of the can.

Add can to top of head.
Add can to top of head. (Image: Lego Body Step 8)

Step 9

Tape duct tape to parchment paper and cut out features for the face.

Cut out features
Cut out features (Image: LEGO Head Step 9)

Step 10

Remove the parchment paper from the back of the duct tape and apply features to your LEGO face. Make sure the eyes line up with the removed slats and also fall where the person who will be wearing the costume's eyes are.

Apply the features.
Apply the features. (Image: LEGO Head Step 10)

Step 11

Using an X-acto knife, cut out little circles in the middle of the eyes. Use a permanent pen to color the yellow foam rim black.

Black out the rim.
Black out the rim. (Image: LEGO Head Step 11)

LEGO Body

Step 1

Using scissors, remove the top four flaps from the top of your box.

Cut off top flaps.
Cut off top flaps. (Image: LEGO Body Step 1)

Step 2

Cut box in exactly half width-wise.

Narrow box.
Narrow box. (Image: LEGO Body Step 2)

Step 3

Tape the two halves together to make a rectangular 14 inch x 7 inch box with an open bottom. This size will fit a 3 to 4 year old. Adjust accordingly for a bigger body.

Make a rectangular box.
Make a rectangular box. (Image: LEGO Body Step 3)

Step 4

Using an X-acto knife and a 7 inch circle template, cut a hole in the top center of the box. This will be where the head will come through.

Make hole for the head.
Make hole for the head. (Image: LEGO Body Step 4)

Step 5

Use your roll of duct tape as a circle-template, make two circles where the arms will come through the box.

Make holes for the arms.
Make holes for the arms. (Image: LEGO Body Step 5)

Step 6

Cut two pieces of paper to cover the front of each side of the box, flaring two inches on either side at the bottom. One should be long enough to wrap over the top of the box. The other should be long enough to overlap the top of the first sheet slightly.

Cut the paper.
Cut the paper. (Image: LEGO Body Step 6)

Step 7

Apply thin ribbons of white glue to the paper on each side of the box. Stick paper to the box.

Glue paper to the box.
Glue paper to the box. (Image: LEGO Body Step 7)

Step 8

Measure sides of the box and cut orange paper to cover each side. Cut holes out of paper with an X-acto knife.

Cut out holes.
Cut out holes. (Image: LEGO Body Step 8)

Step 9

Using various types of tape, look at a LEGO and design a construction worker vest with pockets and a collar.

Design your vest.
Design your vest. (Image: LEGO Body Step 9)

LEGO Hands

Step 1

Cut 5 inches off the top of a Pringles can. Notch out an inch piece then cut it into two 2 1/2 inch x 8 1/2 inch pieces.

Make hands.
Make hands. (Image: LEGO Hands Step 1)

Step 2

Cut a piece of yellow foam big enough to double over each round 5 inches x 8 1/2 inches. Hot glue it to your cardboard, folding over one edge.

Cover cardboard with foam.
Cover cardboard with foam. (Image: LEGO Hands Step 2)

Step 3

Puncture the middle of the "hand" with your X-acto knife, insert a #2 pencil through the hole and hot glue a piece of foam to cover the eraser.

Make handles for the hand.
Make handles for the hand. (Image: LEGO Hands Step 3)

LEGO Legs

Step 1

Cut two pieces of cardboard that measure the same width of the front of the "body" when they are next to each other and are the length of the costume wearer's actual legs. I used two of the flaps of the square box. Cut a Pringles container the width of one of them, and cut the container in half, taping each half to each side of the top of the "leg".

Add bumps to legs.
Add bumps to legs. (Image: LEGO Legs Step 1)

Step 2

Cut two additional pieces of cardboard that are the same size as the front of the legs.

Cut two more pieces of cardboard.
Cut two more pieces of cardboard. (Image: LEGO Legs Step 2)

Step 3

Use the top of your Pringles cans, trace 4 semi-circles.

Trace semi-circles.
Trace semi-circles. (Image: LEGO Legs Step 3)

Step 4

Cut out the semi-circles leaving a 1/2 inch extra around the traced line and notching the extra space every 1/4 inch up to the line.

Notch semi-circles.
Notch semi-circles. (Image: LEGO Legs Step 4)

Step 5

Cover each side of the halved-Pringles cans with the half-circles. Wrap the notched edges around the sides and tape in place.

Cover sides of semi-circles.
Cover sides of semi-circles. (Image: LEGO Legs Step 5)

Step 6

Add the second piece of cardboard adjacent to the first. Cover the bump and front of the leg with white glue and cover with florescent orange paper. Cover the side pieces of cardboard with orange paper.

Cover leg with paper.
Cover leg with paper. (Image: LEGO Legs Step 6)

Step 7

Use your light grey tape to decorate the pants. The "pants" are to be duct taped to the bottom of the box from the inside after the "body" is put on.

Decorate the legs.
Decorate the legs. (Image: LEGO Legs Step 7)

Step 8

Your LEGO Construction Worker is ready for a night of trick-or-treating!

Your LEGO Construction Worker is ready!
Your LEGO Construction Worker is ready! (Image: Lego Construction Worker)

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