Surly Duff

I've wanted to make this costume for years now, and we finally had a good reason. My office has a Halloween costume party every year, and we were invited to a party at a co-workers house last night.
Surly Duff is a Simpsons character, one of the 7 Duff beers at Duff Gardens. He is the only one with a speaking role: "Surly only looks out for one guy- Surly."

I won't bore you with details of the construction, but it took a couple of weeks and involved a 3D computer model and a 36" HP plotter printer. It's felt supported with foam rubber, and the label is made of felt. Sarah did a fantastic job of sewing all of the parts together, especially the cap. I'm really happy with the way it turned out.

Happy Halloween!