I started conjuring up Buzz Lightyear in August. I researched a TON of home made Buzz costumes, female versions and full armor replicas. Even though I planned so much, it came out way different than I expected...and everything is hand sewn, hand painted and hot glued (except the corset and the skirt)
Craftser - http://www.craftster.org/forum/index.php?topic=394211.0
Coolest Homemade Costumes - http://www.coolest-homemade-costumes.com/buzz-lightyear-costume.html
RPF (Where I got the decal templates)http://www.therpf.com/f24/buzz-lightyear-costume-ideas-89095/
I also watched the movie, I even used photoshop and took a still frame of Buzz and made the exact shape into the chest plate but we'll get to that later...
Alright then...where to begin....
I have the top over a black leather corset. The top is made of a sweatshirt, the sleeves were cut off and turned into leg warmers (The wrist cuff is at my knee, I have white leggings on too) and a turtleneck was sewn underneath. The gauntlets were bought but I cut the fingers off and attached a laser to my right wrist (you can see it peeking)
All "decals" were hand painted. The chest plate is made of a thin foam yoga mat. I made a pattern directly from a still of Buzz in Toy Story. I cut out 3 identical pieces and layered them with hot glue. Everything is covered in fleece. The buttons are wood, my laser button is beer bottle caps....
If I couldn't get these wings, I wasn't going to bother being Buzz.http://collider.com/toy-story-3-at-toy-fair-take-a-look-at-the-toys-disney-pixar-will-sell-you-later-this-year/16677/toy-story-3-buzz-lightyear-deluxe-action-wing-pack/
They open and close with the push of a button, they light up and they talk.
They are also extremely expensive. I was lucky enough to find a pair on Craigslist for dirt cheap. I was so excited...until the voice mechanism immediately gave out.
I had to rerig it anyways because the chest plate was child size, but at that point I also had to take the whole thing apart. Turns out I just had to shorted the speaker wire because it was shredded inside. I soldered for the first time! I used soldering paste, but I did good! here is a back shot of the wiring all electrical taped. The speaker was tucked into the green part but I took it out to show it off to you guys.
I made new straps from purple ribbon and covered that halfway in green fleece. The button to open the wings was originally on the chest but I had to move it to my shoulder because it wouldn't reach. I mean it was built for a child so...
Here is a closeup shot of my Pizza Planet Alien. I patterned it after a winter hat he wears and hand sewed it. The eyes are made of cat toys and hot glue. The antennae is glued to a headband which the hat hides, so that it will stand straight up.
I painted the Pizza Planet logo on this shirt which houses a squeaker. He isn't as high tech as Buzz, but a simple piece to a dog toy really made it that much more special.
...Oh, I almost forgot! I was going to make my gloves but they were too bulky and I didn't want to waste this painting, so I made it into a small purse =0)
I slaved over this buzz Lightyear costume...but the fun I had in it was incredibly worth it. People who were already in awe that I made them myself nearly exploded when my wings came out by themselves.