DIY Astronaut Costume

5, 4, 3, 2, 1…Blast off! My little boy is on his way to outer space.

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We are so thrilled and proud of how this costume turned out! There weren’t too many tutorials and it looked pretty complex and intimidating to make, but we accepted the challenge. It took over 15hrs to make but it was well worth all the time and prep. So happy to be sharing this tutorial with you.

Here’s a step-by-step on how we put it all together.

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To make the flames we started by making a simple skirt. We used an old orange (or you can use red) t-shirt with an added elastic waistband so he could easily slip in and out of it.

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Then, we cut triangles from yellow, red and orange fabric (mostly from scrap fabric and old t-shirts). Hot glued them onto the skirt – starting from the bottom and moving up. Note, triangle pieces toward bottom of skirt are smaller and gradually get larger toward the top.

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For the rocket pack, we used cardboard, hot glue and duct tape. The bottom is left open for his legs while the top is closed. Underneath is a large opening where his body will fit – better view in photos below.

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To give it some dimension, we added more cardboard details. To bend the cardboard into cylinders we scored it with an hobby knife first.

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Cut slits in cardboard and inserted elastic for straps so he could wear it like a backpack.

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Painted it white and added some spaceship logos to make it look official.

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We lucked out and found a kid’s space suit from Marshall’s. Cut a horizontal slit in the back of the space suit. Stitched it loosely around the opening to keep the filling from falling out.

Now for the ‘fake’ legs – these were tricky.

This took quite some thought to figure out:

1. What materials to use to keep it light weight

2. How to get them to bend (and stay bent)

3. How to attach them to his body

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 We decided to use cardboard and a pool noodle. Cut the cardboard and pool noodle like above.

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Attached pool noodles to cardboard using hot glue and duct tape. Leave 1-2 inches of cardboard to attach to piece below.

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The rectangular piece of cardboard will be the piece that’s against the body.

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Insert and glue/tape from the front and behind.

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Added the thick black strap which will go behind his neck.

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Threaded a belt into the cardboard to secure the legs around his waist and keep them from falling.

Assembling the outfit can be tricky so here’s a walk through…

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Put on flame skirt

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Wear the space suit by entering thru the open slit in the back.

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Buckle the belt.

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The space suit came with these fabric boots which were perfect because they were super light weight and we didn’t have to figure out how to attach real shoes/boots to the outfit.

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Insert legs into the opening of rocket pack. Pull rocket pack up and wear backpack straps. Note: Wear red/orange shoes to blend in with flames.

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And…BLAST OFF!

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We can’t get over how real this looks!

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Cost breakdown:

The only thing we purchased for this costume was the space suit (found at Marshall’s for $25), a pool noodle ($2) and some fabric for the flames ($2) – Total cost, $29.

This was definitely one of the most challenging costumes we made to date. We learned a lot about engineering and construction along the way. Hope this inspires you to take on a project that pushes you beyond your comfort zone.

If this tutorial is helpful and you make your own version we’d love to hear from you!

This costume was 1 of 4 space themed costumes we made for our family this year.

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Check out tutorials for the moon, space shuttle and big dipper constellation costumes.

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