Technology, beer, fitness and kids

Bud Light Batman Build (Budman)

Not sure how exactly this came about, but having always wanted a Batman costume, and stumbling across an online tutorial, I decided to make one out of Bud Light beer boxes. Call them cases, cartons, two-fours, whatever you like based on where you live. Here is a breakdown of how I made it & general tips along the way.

If you have any questions, follow me on Twitter & send me a message @legoszm.

1) Do everything in paper first, & tape it together. This is great for getting the size right.
2) Printing as PDFs lets you resize to fit in percentages. Poster it across multiple pages, and tape together.
3) Cut out your templates carefully. Consider using a sharp utility knife with a metal ruler.
4) Place the template on card. Only mark each corner.
5) Connect the dots with above mentioned ruler.
6) Use your utility knife to cut the card exactly.
7) Pre-fold/bend your pieces before gluing.
8) Cut slight angles on your edges so the glue gets pushed to the back & the join is seamless (as it can be).
9) Glue slowly. Hot glue gun is usually good enough. One edge at a time. Pre-bending the cardboard as much as possible will help.
10) Have your paper prototype handy as a reference.
11) Consider starting with something simpler than a mask. Even make a little box or something.

If you own one of the templates I have referenced below, I’m happy to remove/relink/credit as per your wishes.

Completed so far

Batman Cowl/Mask
This is what started it all. I pretty much followed this exactly.

This template is great. Easy to make edges. Depending on your body proportions, you may need to increase the size, or in my case, add additional pieces on top, and to the sides to close it out.

Abs/lower Chest
I totally freehanded this. Lots of examples online. Work with paper and tape

Shoulder & Biceps
I took these from a Dark Knight template. Download the Pepakura Viewer app, & get the file below. You can then cherry pick which pieces in the model, locate them on the paper, then rearrange & print only what you need. Print to PDF, then size using Adobes features. I do not recall where I got this template from.


These were another great Instructable find. Here is the full link with all the PDFs for most of a complete costume.

They seem to be cross-ish posted here too:

And here are the two I used for the gauntlet, hosted locally here.

Utility Belt

I need it to be functional in a number of ways:

  1. Keep my glasses when I’m wearing the cowl
  2. Somewhere to put my phone
  3. Keep my pants up
  4. Use to hold up the remaining leg armor

I also wanted to keep the work to a minimum, time is getting away and Halloween will be here closer than we know.

So I used some KD boxes, and cut them to be shorter and narrower. A few small boxes that I did the same thing to. I then unfolded some instant oatmeal boxes. These will cover the generic belt.

Got some red spray-paint. 4 coats seemed to be enough.

Then I’ve glued Budweiser beer labels to some thin card, which I’lll cut out a Batman symbol.

More photos to come.

After preparing the cardboard above, I then cut the large flats into strips, looping them around an old belt. Used an online Bat symbol to create the buckle, then glued it onto spare Bug Light box card.

This is just a test fitting. Have to figure out how to attach the boxes to the belt, after the belt has been put on. Likely using bulldog clips or similar.

Items I’ve yet to start working on

  1. Neck – Looking at an Iron Man template for this.
  2. Upper chest – Thinking I will freehand based around where everything else sits/fits.
  3. Thighs
  4. Lower Legs
  5. Shoes/Feet
  6. Cape – Will likely buy a Bud Light flag from Amazon.