My boy is a lego freak (as was I at his age) so we decided to do a lego minifig for his costume. I didn't take any photos while building it, but here are a few I have. It's made out of styrofoam that I cut and hollowed out. I used open cell foam (not really the right stuff) because I had it on hand. The worst part was trying to get a smooth finish on it. It's far from perfect, but after 3 times of the fill/sand routine I was over it. I coated it with 3 coats of latex primer, then filled with light weight Spackle...repeat 3 times. Then I sprayed it with yellow, did the eyes and mouth, and clear coated it. I have one hell of a mess to clean up in my garage, but it was fun, and he really digs it. I did a body too that will be worn under a shirt to give him a "boxy" look. I'll post pics when I get them.