COSTUME: Handmade
Pretty darned proud of this fella.
Got fed up waiting for Toybiz. Took a Hulk FC, cut off a finger and sculpted over his existing head, hands and feet with milliput. Left it to *just* start drying before 'carving' in the details (cleaner and easier that way).
As for the body - improvised on an idea from Elmeaux; used a black lycra body suit onto which I glued lots of bit of orange craft foam (a jigsaw puzzle from Hell!) using a latex-based adhesive. Do it carefully and he should keep a pretty wide range of movement. Had to still paint the foam though - it was a slightly different shade to the acrylic paint I used for the milliputted bits.
A quick pair of shorts were fitted and my FF was complete (already done the Human Torch)
What you'll need;
(1) Hulk FC
(2) Milliput/super-sculpey or whatever
(3) Black lycra, blue lycra and black vinyl
(4) Orange craft foam
(5) Orange, black and blue paints
Stage 1 - Cut down Hulk's hair and ears slightly - this'll stop The Thing's head from being too large. While you've got the craft knife handy also slice off one of the Hulk's fingers (I removed the one next to his thumb).
Stage 2 - Mix up your milliput, mold on around the head (leave the Hulk's eyes looking out though), hands and feet. Leave for 30-45 mins until the compound just begins to harden then 'etch' in the cracks with a pointy screwdriver/cocktail stick/etc. Smooth down any fingerprints etc. Leave to dry for 24 hours
(if you use another modelling material cure it however the instructions suggest)
(and remember the Thing only has 4 fingers on each hand, and 4 toes on each foot!)
Stage 3 - Make up a rough one-piece body suit pattern (unfortunately I've lost mine, but I based it on an enlarged M2 pattern... try squeezing a spare M2 costume onto the Thing and work out from there where the pattern will need to be altered). Your pattern should resemble something like... ( and remember to err on the side of bigger rather than smaller)
Stage 4 - Cross your fingers and put the costume on the Hulk/Thing. With luck it should fit? If not you can take it in where necessary (or start all over again if it's too small). Sew the back of the costume closed. The overall quality of the sewing doesn't matter - ditto the finishing around the cuffs etc. as the next stage will help hide all that.
Stage 5 - Craft foam. Take a sheet of orange craft foam and start cutting off lots of different sizes and shapes. I found it easier to just have a pile of bits rahter than trying to cut sections to fit. Take your glue and start sticking these to the Thing. I found smaller bits 'inside' the joints helped keep a reasonable amount of movement. Don't worry if you get blobs visible on the black lycra... you can always paint this out with black once you've finished. You might need a cocktail stick again to help place the tiny 'rock' fragments (have a picture of the Thing handy to give you a rough guide as to the shapes needed)
Stage 6 - Paint the hands, feet and head... and the foam (don't worry about the sides of the foam, just the front section); the paint gives the foam a better looking finish. Paint in the cracks with black. Touch up again with orange ;-) Paint The Hulk's eye's blue (thinks... this might be best done before the the sculpting?).
Stage 7 - Using your pattern again, use that to draw up another for his shorts. Cut out (this time placing the crotch on the fold). Sew up, hem the leg holes (a thin layer of the latex-based glue should do it - check first on a rough piece to make sure it doesn't bleed through). Slip them on The Thing. Cut out a belt strip of black vinyl, spot more latex glue on the top rim of his shorts will help hold it in place while you superglue the belt together around his back.
... and there he is; one Thing ready to go a clobberin'