Instructable has a great HOWTO for making your own Ghostbuster costume this Hallowe'en:
Start making the pack!
This is that hard part. Study all the plans over and over. The motherboard is made from 1/8" thick board and is bolted to the ALICE pack frame. The spacer is made from blue foam as are the gearboxes, Ion arm and bumper- this speeds things up dramatically and really cuts down the weight of the pack. The cyclotron is made from MDF rings and 1/8" thick board. I ended up using flashlight refelectors with red LED's in them for the cylotron lights. The lenses were made from translucent plastic folders.
The powercell is made from 1/8" thick board and is held in place with screws, making it easy to remove for battery access. I used another plastic folder (blue) to make the powecell lense. I made the gun hook from a piece of 1/8" thick aluminum sheet but a lot of people use a Dixie cup dispenser hook. I machined my own knobs and Ion knob but many people use stacked washers for the Ion knob. The N-filter was made from a can.
The trick to working with foam is to finish it properly or paint will melt it. Once your foam is cut to shape sand it lightly and smooth all the surfaces with a lightweight spackling paste. Then cover it with Minwax Polycrylic sealer. This will allow you to paint it with good old black spray paint. It will also make the foam a little tougher.
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