How to Make a Plug & Socket Costume

Measure the distance from hip to hip and front to back just below the waist on the person who will wear the plug costume. Cut the 8- to 10-inch thick foam 6 inches larger than the hip measurement and 10 inches larger than the distance from the front to the back. For example, a person who is 20 inches across and 12 inches from front to back requires a piece of foam that measures 22 by 24 inches.

Place the rectangular piece of foam on a flat work surface. The example creates a rectangle that is 24 inches wide, 22 inches from front to back and 8- to 10-inches thick.

Center and cut an opening with a serrated knife from top to bottom in the foam rectangle large enough to fit over the hips on the person who is the plug. Position the opening so the back of the oval begins 2 inches from the back of the rectangle. This creates a large area in the front for the plug.

Ask the person who is the plug to slip the foam over her hips. Measure the distance from the top of the foam plug, over the shoulder and down the back to the top of the plug. Add 4 inches to the measurement. Cut two pieces of white fabric 4 inches wide and the predetermined length.

Ask the person to remove the foam plug from her hips. Hot glue the fabric to the inside of the foam plug opening to use as suspenders. Overlap each end of fabric by 2 inches to secure to the inside of the plug opening.

Cut two holes slightly smaller than the end of the cardboard paper towel tube in the front of the plug about 8 inches apart.

Hot glue a cardboard paper towel tube in each hole. Paint the paper towel tube white.

Measure the distance from two inches below the knee to the shoulders and from shoulder edge to shoulder edge on the person who is the socket. Double the measurement from the knee to the shoulders. Add 2 inches to the shoulder measurement. Cut a piece of black cotton or cotton blend fabric to this length. For example, the knee-to-shoulder measurement is 4 1/2 feet and the measurement across the shoulders is 2 feet. Cut a piece of fabric 9 feet long and 26 inches wide.

Fold the fabric in half so the front side of the fabric is on the inside. For this example, the folded piece of fabric when folded will measure 4 1/2 feet by 26 inches side.

Pin the two 4 1/2 foot edges beginning 8 inches from the fold line. Sew a straight 1/2-inch seam along both edges. Fold the bottom edge up 1 inch and sew a 3/4-inch seam along the bottom edge. The two 8-inch areas below the fold line create the arm holes.

Match the two arm holes together and locate the center of the fold. Hold the mark, place the fabric on a flat work surface and open. Cut a 6-inch slice on each side of the center mark to create a 12-inch opening for the head. Fold the cut edge down 1/2-inch and pin. Sew a 3/8-inch straight seam along the edge to finish.

Turn the socket costume right side out so the seams are on the inside. Place the costume on a flat work surface. Smooth out any wrinkles with your hands.

Cut two pieces of fusible webbing 9 by 12 inches. Center a piece of fusible webbing over a 9- by 12-inch square of gray felt so the paper side of the fusible webbing is up. Iron the fusible webbing to the felt. Repeat the process with the second piece of gray felt.

Place the gray felt on a flat work surface so the paper portion of the fusible webbing is on top. Draw the desired shape of the socket such as round the edges to create an ova or angle the edges to create an octagon. Draw two ovals 1 1/2-inch wide and 4 inches long approximately 8 inches apart in the center of the fusible webbing paper.

Cut along the drawn lines to create two sockets. Remove the paper from the fusible webbing.

Position the two gray felt sockets in the center of the black fabric. Place one socket on top of the other approximately 2 feet apart. Ensure that the fusible webbing is on the back of the felt. Iron into place.