I used styrofoam to make a torso and head for the costume. I got a 2x4 foot sheet at Home Depot. I think it was $6.  The chief reason to use styrofoam is that it is lightweight.

I drew a chest shape and cut it out. That is the same knife I used to cut the hell out of my thumb a few years ago, so I always use it with caution.

The two-inch styrofoam wasn't thick enough, so I cut a second chest shape, using the first as a guide.

Three ovals would make a nice head.

Front view of my rough styrofoam head.

I dug out a little channel for a pvc tube, and taped the three thicknesses of head together.

Taa Daa! Head on a stick.

This is just to keep strangers out of my backyard. 

Now onto the costume!

The head and chest together. Next he needed some arms.

I used a long section of pvc pipe for the arms.

In this photo, I recreated the walk-off scene from Zoolander.

A few minutes with an angry heat gun, and my arm pipe was permanently bent.

The photo shows both hands attached.

Another channel cut in my styro-torso allows my arms to pivot up and down.

The first one worked out pretty well, and soon he had a twin brother!

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