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Here is how we did it.
Kang and Kodos were constructed from a PVC harness that fit over the shoulders ($1.00 per 5ft length), with lighter, more flexible tubes forming the basic shape (also cheap). The skin of the costumes was made from carpet padding, which is rather heavy, but is also VERY inexpensive and works well for those of us on a tight budget. It holds together extremely well with hot-melt glue (it is actually stronger where you glue it, than it normally is) and is not difficult to form into shapes. We then covered the foam in green fleece (The most expensive part of the costume, but still not unreasonable), once again using hot-melt glue to secure it. The eyeballs are made from Celucaly (paper mache) and the teeth were made from sheets of craft foam, you can buy at almost any craft store for about a dollar a sheet. The rest is all a matter of time and artistic talent. We spent all year working on these, slowly over time, and when all was said and done, we had only spent about one hundred dollars on each costume. Spending two hundred dollars on this project may sound a bit high, but honestly, two hundred dollars spread out slowly over an entire year is not a big deal.