R2D2 DIY Costume

Posted by Holly Marsh on

We're nearly halfway through October, and this usually means my husband (or I) are halfway through a costume build.


While I'm not going to show you the costumes for this year (they're not done yet!), I will show you last year's costume.

We've worked with duct tape, fabric, cardboard, paper maché, etc. in past years.  Sometimes we make costumes for everybody, but last year there was only time and energy for one.

And it was a doozy. And it was allll Rob this time.

DIY R2D2 Costume

Beep Beep Boop Boop! It's R2D2!

Of COURSE The Boy asked to dress as R2D2. Being freshly (mostly) unpacked from the move from Portland to Astoria, we were (somewhat) ready to do some Halloween costume building.

Not to mention at the time there was NO decent R2D2 costume you could buy that would suffice. 

It took Rob about six weeks to prep, plan, and build. He started with a cardboard "skeleton" of sorts. 

He used a hot glue gun to adhere all the pieces together, and then used white poster board to wrap some of the parts (like the top of R2D2's legs).

He then used more white poster board and duct-tape-covered cardboard pieces to build the main body for R2 and all his little components (this is where blue, white, and silver metallic duct tape came in handy!).


He also had to think about how The Boy would be able to go trick-or-treating in this costume. The Boy, four years old at the time, had never gone trick-or-treating. I know, I know, cue the pitchforks and torches, for I am a "Terrible Parent." But sorrynotsorry, I don't see how trick-or-treating benefits any kids under the age of four; he wouldn't have gotten any of the candy before then, so it's never been an issue. This year we felt he was ready.

Rob made little openings in R2D2's front where The Boy could stick out his hands and receive his hard-earned candy. They stayed shut via adhesive Velcro dots.

He configured a strap system so the costume would rest on The Boy's shoulders, and the hat stayed on via a strap that rested under his chin. The hat was made of cardboard, poster board, and duct tape, and Rob filled the inside with foam cushion pieces to where it fit snug, yet comfortable on The Boy's head.

The rest of the family dressed up like Star Wars characters, but these were purchased costumes.

DIY R2D2 Costume

Rob's Chewie hoodie: ThinkGeek, BAM's C3PO costume: Amazon.com, My Han Solo costume: shirt: Fred Meyer clearance section!, vest: Goodwill, and pants: TeeFury.

While I had purchased my Han Solo leggings on TeeFury, I seriously considered buying navy blue leggings, and adding the red strips on the side with duct tape. It would have been a more authentic look. ;)

We went trick-or-treating downtown, and the local businesses of Astoria open up for trick-or-treating. We had a huge downpour all day, so I worried he wouldn't want to go, but the rain let up just as we arrived downtown. 

DIY R2D2 Costume

I was concerned the costume wouldn't hold up in the rain very well, but it was just fine to trick-or-treat for some candy downtown and then attend the Monster Bash at the Armory.

The Monster Bash was a ton of fun! There were games and activities, and of course, a costume contest. The Boy totally won Best Costume for his age group.

 DIY R2D2 Costume

R2D2 now protects The Boy's room, so it's been useful long after Halloween. 

Now to keep working on this year's costumes! Are you or your littles dressing up for Halloween this year? Tell me about your costume in the comments!


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