Making sam
Here's the final product. Scroll down to see the process of making Sam.
I ordered an orange onsie from All-in-One company. I got mine with all parts orange. I had the feet come attached. I got a high collar put on so that the costume goes up into the mask and my neck cannot be seen. I had the zipper put in the back so it does not take away from the front of the cosplay. I also had zipper pockets put in, but that was just a personal preference for conventions.
I added mustard yellow patches made from felt to the front and back of the onesie. I attached them using fabric glue. I then used a mixture of different paints to dirty up the front and back of the onesie. I also made sure to make sure that the white fabric attaching the legs and the feet were nice and dirty lookkng so that they didn't stand out.
So through some googling I found this rat exercise ball. (Kinda like a hampster ball, but larger). This one is 13 inches in diameter. I cut along the already placed slits down to the opening and cut it four slits across. Next I cut those same four slits up to the halfway point of the ball. Then I put duct tape along the edges that I cut and tried it on.
Last step was to make the mask. I found some burlap I had laying around. I doubled it up so my mask is actually two layers of fabric. I placed it over the head and pinned where it needed to be to make it a sphere shape. I then used my sewing machine to sew where I had pinned. Then I usdd twine to sew stitching running vertically along the center of his face. The buttons that I found that were the right size were the wrong color and only had two holes in them. (I needed four.) So I painted them, and used my drill with a drill bit to add two more holes to the buttons. I then used the same twine from before to attach them to the mask.
This is with the smile added.
This photo is simply here to give you an idea of what the mask looks like when it’s not on. When you tie the rope around the neck it pulls it in into the sphere shape around the head.
Last step was to put everything on and check to make sure it all looked good. I also bought brown gloves that I cut the fingers off of, and used the same dirtying step as for the onesie to dirty up a pillow case for his bag.