Rex | Toy Story

Nick Behling · October 31

Rex, the lovable green dinosaur from the Toy Story franchise, captures hearts with his endearing personality and gentle demeanor. Although he may look intimidating with his large head and dino legs, Rex embodies a character defined by his fears and insecurities. As a plastic toy brought to life, he represents the universal struggle of feeling out of place, making him relatable to fans of all ages. This tutorial will guide you in creating a Rex cosplay that showcases not just his dinosaur features, but also his affectionate and anxious spirit.

Key to bringing Rex to life is capturing his distinctive features: his oversized head, tiny arms, and charmingly awkward legs and tail. It’s essential to emphasize the "toy" seams that highlight his identity as a beloved plaything rather than a real dinosaur. By focusing on these elements, you can create a costume that celebrates Rex’s character and reminds us all of the joy and innocence found in childhood toys. So, let’s dive into the steps to transform yourself into this iconic character and embrace Rex’s unique blend of bravery and vulnerability!

Step 1: Sculpt the Basic Shape

Start by using clay to sculpt the basic shape of Rex on a 12-inch posable wooden human figure. Focus on creating the head, legs, and body. Take your time to get the proportions right; this will serve as the foundation for your costume.

Step 2: Create a Tape Pattern
Once your sculpture is complete, cover it with masking tape. Make sure to wrap it snugly to capture all the details. Carefully cut the tape off in a way that creates a flat pattern. Lay this tape pattern onto a piece of paper and scan it into your computer to create a digital template.

Step 3: Project the Pattern
Using a projector, display the scanned pattern onto the ground or a large wall. Adjust the size as needed, then trace the pattern onto EVA foam. This will serve as the base material for your costume.

Step 4: Cut and Assemble the Foam
Carefully cut out the traced shapes from the EVA foam. Use contact cement to glue the pieces together, forming a full-scale 3D version of your pattern. Ensure everything aligns properly as you build up the costume.

Step 5: Fit Test
Once your foam structure is assembled, try it on to check for scale and size. Make any necessary adjustments to ensure it fits comfortably. Once you're satisfied with the fit, you can move on to adding details.

Step 6: Scale Application
Using 2mm foam, cut out individual scales to represent Rex's texture. Glue these scales to the body using contact cement. Layer them for a more realistic look, making sure to cover all visible areas.

Step 7: Create the Illusion of Teeth
To give Rex a toothy grin, glue plastic Easter eggs along the jawline. Position them carefully to create a convincing appearance of teeth.

Step 8: Conceal Your Face
To hide your face inside the costume, attach a screen on the inside of the head. This will help maintain the character's look while allowing you to see out.

Step 9: Craft the Eyes
For the eyes, use more plastic Easter eggs and draw pupils on them. Secure them into place to complete the facial features.

Step 10: Sew the Shirt
Sew a green shirt with arms to serve as the base for Rex's arms. Ensure it fits well, and consider adding details or textures that match the character.

Step 11: Attach the Feet
Glue a pair of rubber shoes to the bottom of the legs using contact cement. This will give your costume stability and make it easier to walk in.

Step 12: Seal the Costume
To protect the foam and add durability, spray the entire costume with aerosol flex seal. This will also help create a smooth surface for painting.

Step 13: Base Coat with Green Paint
Once the flex seal is dry, paint the entire costume green. Use acrylic or spray paint, and apply multiple coats for even coverage.

Step 14: Add Texture Details
Using other colors of paint, add texture and details to your costume. Consider using sponges or brushes to create different effects and depth.

Step 15: Get Into the Costume
To wear the costume, climb in through the bottom. Ensure that everything feels comfortable and secure before final adjustments.

Step 16: Attach the Head
Place the head onto the body, aligning it carefully. Make sure it fits snugly to maintain the overall look of the costume.

Step 17: Step into the Legs
Finally, step into the legs of your Rex costume. Once everything is in place and secure, you’re ready to show off your creation!