Gizmodo reader Rob Hoffmann sent in a photo of his Halloween costume: a giant LEGO minifig!
The head is made from chicken wire (1/4 in. square mesh), yellow vinyl, some cotton batting (the mesh would have shown through the vinyl if I didn't use it), and black cloth mesh for the eyes and mouth" Rob told us, "the nub is also chicken wire and vinyl stuffed with foam. You can't tell from the pictures, but it does say LEGO across the top.
The body is made from foam board and a long sleeve mock turtle neck T-shirt. The cloves are made from yellow vinyl and chicken wire (to maintain the shape). The legs are made from a large pair of scrub pants with foam board around the waist so it would fit into the body. I also had suspenders made from elastic to help keep them up.
Link - Thanks Anne!