my boyfriend's making a pterodactyl costume - any ideas?

Answer 1

http://www.hgtv.com/hgtv/dc_occasions_halloween/article/0,,HGTV_3475_1392003,00.html

That link will help him to make a bird costume, that he can make some changes to so that it looks more like a pterodactyl.

Since they look similar (although the pterodactyl is obviously much bigger and the head is different), the basic bird pattern will be a good place to start.