Dad Made: Nintendo Samus Aran & Megaman X Halloween Costumes DIY


When my kids decided what they wanted to be for Halloween this year; Metroid’s Samas Aran (Varia suit) for the girl and Megaman X (light armor) for the boy – my husband, a home builder and old-school Nintendo fan ordered stacks of EVA foam to make their costumes.


I wasn’t too sure what to think when our dining room turned into a DIY cosplay crafting station in July and I had no idea that he’d somehow turn piles of what looked like gym mats into pretty cool costumes using a heat gun, spray-paint, and a few other supplies.


Wanna know how he did it? Check out his steps below:


  • EVA Foam
  • Retractable utility knives
  • Heat gun
  • Plasti-dip for priming
  • Rustoleum aerosol paint for color
  • Glue Gun
  • Velcro
  • bodysuits and black iron-on vinyl
  • Caulk gun and caulking tube to close seams between pieces if needed
  • old helmets


He went with EVA foam because it’s dense and porous and can easily be cut with razor blades.  Starting with hand-drawn paper templates for every single piece – he then cut, heated and bent the EVA foam into shape. He primed everything with plasti-dip to close all the pores and get the material ready for painting.  He ordered body suits (AKA unitards) for the kids on Amazon and lined them with Velcro to attach each piece of “armor” to the bodysuit. The Megaman X bodysuit was decorated with hand-drawn designs that were cut and secured with fusible black vinyl. The Helmets – an old Razor helmet, and sports helmet were picked up at a thrift store and modified.  The shoulder “pads” on the Samus Aran costume were made out of styrofoam balls and EVA foam.  The final touches of paint were first coated in color and then distressed using black acrylic paint and metallic paints to create scuffing and scratches.


The kids are stoked for Halloween – and my dining room has almost fully recovered.


I think it’s safe to say that the girl is officially over her Princess phase.

This one builds her own castles (or blows them up if she feels like it).


And their dad could totally have a cosplay side-hustle if the home design business ever gets boring. Check out his fun video here:

A post shared by Bob Marino (@marinobob) on


Happy Halloween!



  1. Those costumes are absolutely INCREDIBLE. I am completely blown away by the awesomeness.

  2. OMG I love this so much! Your husband should make these to sell, I’m sure they would snap these up in my neighborhood super fast! Great Photos too! 🙂

  3. Wow, I’m so impressed! These costumes are so cool! I never would have guessed your husband made them.

  4. Wow these are the best dad made costumes ever. I am all about homemade Halloween costumes. Thes are adorable and perfect for video game lovers!

  5. These costumes are amazing. They look like they would fit in on set at a movie.

  6. I don’t think I’ve ever seen cooler homemade costumers! Simply incredible! Your kids are going to blow all of the other costumes out of the water this year.

  7. WOW! These DIY costumes are beyond cool and they’re really perfect for Halloween. I’m impressed with the outcome and I’m sure the kids will love it too.

  8. This is really impressive and I admire the talent in creating super awesome costumes! I have never tried making DIY costumes before but you’ve inspired me to do so!

  9. Wow! I am just so impressed! These turned out so well! I would like to wear one of these ha ha. I don’t think my DIY costumes would turn out so well.

  10. Those are freaking cool costumes! Those kids are definitely lucky!

  11. Those costumes are amazing! They look so professional! My mom made our costumes every year- so I know the amount of work that can go into them. Great job!

  12. Oh my gosh – their costumes are awesome! I love how cool and creative they look! So much fun!

  13. WOW!! These costumes are so amazing! What a great job you did – I cannot believe they are DIY-ed! Definitely some of the best costumes ever!

  14. What? What? What? He MADE those? Talk about an awesome job, those are some of the best costumes I’ve seen. I know he must be thrilled with how great they turned out. Big kudos for the unique and cool factors!

  15. Annemarie LeBlanc says

    Wow! Your husband has so much talent! These costumes look like the expensive store bought kinds. Your kids are lucky to have these costumes to wear, and they’d be so proud to let their friends know it was their dad who crafted it for them!

  16. They are the coolest costumes! Normally my mother-in-law makes the kids’ costumes, but she isn’t feeling up to it this year. Love these awesome costumes!

  17. Your kids are so lucky to have a dad who is that creative! OMG. My husband is not in anyway good with crafts. (like me). It sure looks like your kids adore their new Halloween costumes. BTW, did your husband ever think of going into business making kids’ costumes?

  18. wow, these are truly amazing. Great job

  19. Destiny Paquette says

    So amazing. I just love these and how creative and detailed they are.

  20. So your hubby made this??? He is so creative I love this that is awesome I want him to make me a costume now!

  21. Nicole Perrino says

    These are amazing! And I love that looking at them they look like they weigh a ton! So freakin cool!

  22. Wow! Those costumes are incredible! Seriously, your husband can so quit the home business and start making costumes for all occasions. 🙂

  23. Elizabeth Johnson says

    Amazing! That’s insanely creative.

  24. The BEST THING I have ever seen! Can’t wait to see you in a magazine someday.


  1. […] your dad whips up a pretty cool Samus Aran Varia suit and Megaman X light armor cosplay for Halloween, I suppose it’s natural to want to step into that armor more than once. And […]

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