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Disneyland Half 2011: Making My Russell Costume Part I

The Disneyland Half is in 3 weeks, and I'm totally not ready. But at least I'll look awesome. Or stupid. Either one.

I finally started all the DIY and crafty parts of my costume today...including the thing I was worried about the most: the badge-studded sash. This was particularly tricky. I didn't want buy real Boy Scout iron-on badges because I wanted the weird Pixar ones that Russell actually wears. But then there was the problem of execution. I didn't want to replicate and illustrate the badge designs myself because that will make my brain implode. Luckily, I found links to Pixar's concept art of the badges here. Really, I could've just printed these out and glued them onto the sash but I really wanted the badges to have some depth and to look less like stickers and more like fabric and thread. Then I found my secret ingredient at the hardware store... padding felt stickers. Yup, these circles are the perfect shape + size, and each one features a pretty heavy-duty adhesive back, and most importantly- they barely weigh anything. I gave the felt side a few thin coats of flat white spray paint. I printed the badge designs out on some nifty transparent plastic sticker sheets. I cut the sticker sheet badge circles out and stuck them on the felt side of the furniture padders. The texture effect looks absolutely FRAKKIN' AMAZING. The fabric texture totally shows through the transparent colored film- kind of like the surface of a tennis ball.

(I got the Grape Soda badge from this store on Etsy.)

Reader Comments (21)

These look awesome! I wonder what a scout has to do to earn that tornado badge, though.

August 15, 2011 | Unregistered CommenterDavid


August 23, 2011 | Unregistered CommenterDan

How did you know what size to print the badges at? (So they fit on the felt circles)

Any recommendations on where I can get some nifty transparent plastic sticker sheets?

Thanks for the inspiration!

September 8, 2011 | Unregistered CommenterDaniel

Ps. You were by FAR the best costume I saw at the Disneyland 1/2.

September 8, 2011 | Unregistered CommenterDaniel

Pss. Any chance you could link to the Yellow Polo (zappos) and Brown Running Shorts (patagonia)? I'm having trouble finding them. Thanks!

September 8, 2011 | Unregistered CommenterDaniel

- The felt pads were 1.5" in diameter, so I resized the badge images in Photoshop so they're that wide.
- You can get the printable transparent sheets here on Amazon
- The polo and the shorts are actually for women. But here's the guy yellow polo shirt (it's very breathable!) Brown shorts should be fairly easy to find for guys since it's not a popular color for women's active wear.

Thanks so much for liking my costume!

September 8, 2011 | Registered CommenterKaren


Thanks for getting back to me. I remember finishing the Disneyland 1/2 marathon and seeing your costume in the 'Finish Corral'. Being a bit delirious after 13.1 miles I didn't think much of it other than it was the best costume I saw during the race.

It wasn't until a few days later that I thought it would be a perfect Halloween costume. (Especially since UP is my favorite Disney/Pixar movie) I thought I would Google 'disneyland half marathon wilderness explorer costume' in hopes that someone had taken your photo and posted it to their blog. Little did I know I would find your blog with DIY instructions. :)

I did have a few other questions. (And Thanks in advance for all the help!)

1.) When you printed on the transparent sticker paper, did you print on a Laser or Ink Jet printer? Was the felt pad adhesive enough to hold the Badges to your Sash or did you use some extra glue to hold them on?
2.) Where did you find the 'Wilderness Explorer' symbol you used for your Hat and Flag?


September 9, 2011 | Unregistered CommenterDaniel

This is amazing! I'm putting together a Russell costume for Halloween this year and your tutorials and blog have been a great inspiration and help :).

Would it be possible to upload and link the resized badge images? I don't have photoshop, but love the idea of printing them out and putting them on felt stickers.

I am also having a hard time finding a wilderness explorers logo. Where did you find yours for the hat and flag?

Thanks so much!!

October 21, 2011 | Unregistered CommenterHannah

hello! i loooove the badge! im also trying to replicate it but im finding that hard to do. your post helped me a looooot! just a question though, can you please please please send me the badges you resized already? sorry im not really an artsy person and since you already have it, i was wonderin if you'd help me out please. i need this in a week's time and im following your work to the T (hope that's ok with you :) ) and yea, someone asked what printer you used. please do let me know also. thank you, i really hope you could help a stranger out :)

January 15, 2012 | Unregistered CommenterFiona

That's so awesome! My boyfriend as UP (I was Russell, he was Kevin the Bird) as well last year for Disneyland Half Marathon! Wasn't it epic? haha I hope to see you this year!

January 16, 2012 | Unregistered CommenterKathy

Oii, em uma pesquisa procurando imagens dos buttons do Russell cheguei até seu blog, menina você é muito criativa! adorei! beijus

February 29, 2012 | Unregistered CommenterSuelen Souza

I was wondering how you got the picture at such high quality! i resized those images to the 1.5 inch and it is rather pixelated.

June 21, 2012 | Unregistered Commenterbrittany

Would you be interested in making a sash or selling one for me.

August 18, 2012 | Unregistered CommenterChristian

Hello there! I absolutely love love love your idea! My husband and I are going to dress as UP characters for halloween. Your pin idea is fantastic! I was going to by button pins, but I like you DIY pins so much better! Is there any way you would upload a link of the resized badges! PLEASE! :)

October 2, 2012 | Unregistered CommenterCali

Just wondering where you got your wilderness explorer felt badges for your hat?

October 4, 2012 | Unregistered CommenterKayla

Hi - My 13 year old daughter is IN LOVE with this costume and is trying to replicate it. We have all the pieces but dont know how to print out the badges. We have the paper but dont know to resize them to 1.5 like the furniture dealies we got. Is there any chance you would be willing to email them to me in the resolution you used? I would be forever grateful! and would even be willing to send a little donation for your time to a paypal account? Thanks in advance if you can help. Stacy

October 8, 2012 | Unregistered CommenterStacy Brown

ATTENTION EVERYONE TRYING TO MAKE THIS COSTUME: I'm making this costume too and I resized the images and un-pixelated them so they fit on those furniture pads. Mine look GREAT so far. As far as the sticker, I bought Avery brand "Print to the Edge Round Labels, 2" diameter" so I formatted my badges so they print out on those sheets and all I have to do is trim a bit off the edges. If you want copies of my images, just send me an email at

October 12, 2012 | Unregistered CommenterVee

RE: MY HELP WITH THE BADGES- I posted all the resized/un-pixelated badges on this blog [ ] as a means to help everyone that's been emailing me... without you guys having to wait for my responses. Also, I've gotten a LOT of email's about this so this helps me out too, lol :)

October 19, 2012 | Unregistered CommenterVee

Great site! Wonderful costume. Thanks for sharing.

I am trying to make the Russell badges. I went to but cannot print from there. Can you send me directions to print or can you email me the badges?

Thank you.

October 29, 2013 | Unregistered CommenterKathy

Hello. Bob Peterson (one of the directors for UP) went to Dover High School, in Dover, OH. The mascot is a "tornado" hence the tornado badge. Just an FYI :)

March 17, 2014 | Unregistered CommenterKelsey P.

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