There are many pictures, so I'll keep my commentary brief.
The body was upholstery foam. I wanted to use AC foam, but I've forgotten in the years since I worked in real costume shops that that shizz is aspansive.
The back of the face is this sort of heat-pressed plastic felt that I had kicking around from a previous project. The face itself is quilted with Hymark thread through one of my husband's old t-shirts. The rest is covered in Spandex.
The tires and the number are trivets made from old tires that J snagged from Bed, Bath, and Beyond. I guess they are beyond.
The boyo loved his costume, though at the actual party at the park he was done with wearing it for a while. So we let other kids have a go!
Now boyo likes to wear Thomas to dance to the Bee-Gees. He has a hat he wears that for some reason goes with this. He puts it on, and shouts, "All aboard!"
All aboard the disco train! woo woo! woo woo!