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I started this project with one goal in mind, to create ultimate Monsters Inc. costumes. I research different techniques that would make them appear more lifelike (think Bear in the Big Blue House) and less mascot (Sparty).
It boiled down to two things mobility and size relationship. Sully had to be able to dance and get into his classic scare pose.
Then I came up with the Mike and Boo carry costume idea. It helped solve the size relationship problem.
Here are a few clips and photos.