Homemade Sully Costume

My 11 year old daughter is wearing this homemade Sully costume. My kids wanted to be the characters of Monsters Inc this year so her brother is Mike and her sister is Boo. Finding the fabric was the hardest part but I finally found some online. For the body we sewed together a loose fitting one piece outfit that opens in the back. Then I sprayed purple spots in random places with purple hair spray paint. For the tail, I wrapped a pool noodle in the fabric and glued fabric "spikes" along the hem line. The head took the most time. I started with a box about the size of a large shoe box. I cut even slabs of Styrofoam and glued about 3 layers on the top and sides so I could shave it down to a rounded shape. For the front piece (the face), I sketched an outline of Sully's face into the Styrofoam sheet, including horns, and lined it up with the front of the box. I cut the mouth out-large enough for my daughter to see because that area aligns with her eyes. She wanted Sully to be taller than her and that seemed to be the best way to achieve that. I backed the mouth with a black screen. I used smooth Styrofoam balls for the eyes and hand painted the eyes. Then I cut eye sockets into the face and glued them. I sculpted a nose out of leftover 3 sheet thick Styrofoam and painted it blue. Originally I spray painted it but learned really quick that spray pain dissolves Styrofoam! Before I covered his head and face with the fabric, I rolled up felt and glued it above the brow line and cheek line to give it a 3D look. Then I glued the fabric to the face and head. Because it is so furry I didn't have to worry about seems. This costume was a hit at the local fall festival and all the little kids loved her!