A few years back I built a giant Pac-Man costume at the last minute, but it wasn’t good enough for a tinkerer, so I figured that there had to be a way to make it better. What better than to add a functioning mouth to the costume! Thus started the six-week saga of making a giant working Pac-Man costume and matching ghost. These are not projects for the faint-hearted as they take a lot of hard work, and are very large (5 feet tall, 2 feet wide).

Here’s a video of the final product

The shape didn’t turn out the way I had hoped, mostly because I lacked a few tools. A ring roller would have allowed me to add a bend the the CPVC, but I had to rely on tension alone, which created some interesting and unintended shapes.