I decided I wanted to make a Lego minifig costume based off of this post on Make: http://blog.makezine.com/archive/2006/10/homemade_shaun_of_the_dea.html. He didn't post instructions on how he made it, so we just studied lots of pictures and figured it out!
It took me, my husband and my father 23 hours total to make it.
Version 1.0 of the head
Almost all put together, just needed to be painted:
The head is made of styrofoam we hot glued together (first cutting a hole for my head in the bottom layers). The chest area is made of foamcore and the back is a stretchy fabric I dyed blue and attached with velcro. The pants are made out of polyurethane foam hot glued together and held up by some rainbow suspenders my dad had from back in the 70's. The arms are controlled inside with PVC piping and the outside is made with mailing tubes.
One of the Nashville Predators (our NHL team) players is David Legwand. My husband came up with calling my minifig Lego-wand. We wanted people to not just see the 11 and Legowand and miss the "o". So I put a dash in the name. The dash is a painted Lego brick.