Making a Zurg Costume

Zurg's Hat, Cape, Accesories.

Most Important is to have fun making it and wearing it. Hey I'm an over 40 kid and I love taking my Zurg hat to Disney World. OK I love going to Disney World anyway and the Zurg hat adds to the fun. 

OK the hat and cape are the keys to the Zurg look. 

Do you have any Zurg toys around or the how to draw Toy Story 2 book from Disney? Either or both will help. 

The hat is a shield with horns. Get a piece of foam from the sewing store. Sketch the hat to fit the foam. Using a razor knife cut and shape it. I used the razor that they sell to scrape windows. 

Hat from top and bottom
Look Buzz autographed mine at Disney's MGM!

Then get a ball cap and cut off the brim. Cut a hole in the foam and mount it on the ball cap with hot glue. Be sure to slant the foam as Zurg's hat is on a steep rake. Spray pain the horns gray. Cover the hole you cut for the hat with some cloth (and old t shirt works good) and hot glue it on. Mask the horns and paint the center purple.

I got so many "Are you a Vikings fan?" comments I put the aim for the Z on my hat. (Did that with photo transfer sheet, and old t-shirt and glue.)

Click on images to see a bigger photo.

The angle is important!
Notice how the ball cap is level but the Zurg horns slant.

I used glue to hold the foam to the hat!