- September 2nd, 2020, 8:48 am#4938828So here’s a quick summarization of how and what Stay puft was made from. All props were made from fiberglass, latex foam, polyurethane, L200 foam, and 1” white 100 PPI scotfoam.
The head of Stay Puft used red-dyed fiberglass with hand drilled cut out for facial movements. The outer layer was made from latex foam. A helmet was inside the fiberglass skull to wear and leveled out for a view out the mouth hidden within a blackout screen.
The hat was also made with latex foam. For the dark blue band with “Stay Puft” hand-painted on for each (there was one with the text raised) were long strips of polyurethane. The red tie attached to the hat was a single strip of 0.5” red scotfoam.
The bib was made from dark blue 1” scotfoam and hand-painted white strip. Three pieces of foam were used to make the bibs unique shape. The red bow is made from 6 pieces and attaches under the bib.
The torso was originally made for soft urethane foam (fiberglass body would be needed) but in the final build, but changed to a semi-rigid 1” unpainted white scotfoam over a sheet of L200 foam. To allow actors to wear the suit a zipper hidden from view.
The arms and legs were both 1” unpainted white scotfoam over a sheet of L200 foam. all seams were hidden from view. The hands and feet were made differently than the hands were made from latex foam and the feet were made from latex and filled with polyurethane.
Since foam yellows quickly when exposed to light and air over periods, they made big black plastic bags to keep the suits in and keep them clean and white.
Eight Stay Puft Suits were required for the movie, seven burnt, and the hero. All suits were constructed in the same way, however due to them being assembled by hand, there are some very small variations throughout the suits. Thanks to Bill Bryan reviewing my pdf file