How to Make a T-Rex Costume. Calling all dinosaur lovers. Be the king of the dinosaurs and make your own T-Rex costume. This terrifying T-Rex can double as a Godzilla costume for Halloween or movie night. You can make this costume in less than an hour.
Make the T-Rex Skull
Form the skull from a cardboard box. Use masking tape to hold the upper jaw and lower jaw together. The jaw will be made of a 2-inch wide strip of cardboard. Tape these together so the mouth is open slightly or go for the wide, growling jaw.
Tape a strip of cardboard to the center of the top-jaw piece. This is the nose. Use 1-inch wide strips of cardboard to make the shape of the T-Rex's head and the back of his skull.
Now it's time for the paper mache. Mix the water, flour and a little salt to make the paper mache glue mix. Place it in a large bowl.
Cut the newspaper into 2-inch wide pieces. Dip the pieces into the paper mache. Apply them to the skull to make the head of the T-Rex. Allow the paper mache to dry completely.
Roll two small balls of paper mache for the eyes. Cut out small triangles from your extra cardboard for the teeth.
Paint the head green. Paint the eyes and teeth white. Include a black pupil on the eye.
Line the inside, back part of the skull with the egg shell foam so it fits snugly to the back of the wearer's head.
Hot glue the eyes and teeth into the head.
Make the T-Rex Body
Measure the wearer's hands. Cut out two pieces of green material for the right hand and two pieces for the left hand. Attach the two right-hand pieces together with hot glue to make a glove. Be careful to only glue around the seam and to leave an opening for the hand to get into the glove. Repeat the process for the left hand.
Form the tail with the rest of the fabric. Make a green cone shape out of the fabric. Hot glue the seam along the length of the tail to seal the cone in place. Fill the tail with newspapers to make it stiff.
Safety pin the tail onto the seat of the dinosaur lover's sweatpants.
Add LED lights to create eyes. Buy lights powered with a 9-volt battery. Wear the green sweatshirt, sweatpants, head and gloves together to make the costume.