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Kids Halloween Costumes

How to Make a Child's Costume from Recycled Cardboard Boxes

Basics: How to Make a Cardboard Costume


photo by Joe Shlabotnik

Making a Halloween costume is a fun and easy craft project that's inexpensive and fun for children and adults. Cardboard costumes are economical and crafty. Kids love working with paint and the results are creative and spectacular but easy to do.

Decide on a simple shape to cut for the outline. Draw in the basic detail lines, paint and assemble the costume panels to make a "sandwich" costume that fits over clothing and is easy to remove. Be sure your design will be easy for the child to wear. Basic shapes are the easiest to cut and wear.

For example:

  • Butterfly
  • Lady Bug
  • Pumpkin
  • Apple
  • Smiley Face
  • Candy Bar
  • Robot
  • Television

 

Instructions
Step 1
Sketch Out Your Design Shape

Once you've decided on a design, sketch the basic shape onto one piece of corrugated cardboard. This will be the front panel for the costume.

Using the craft knife, cut out the shape's outline from the first piece of cardboard. After you've cut out the front panel, use it as a pattern to trace the same shape onto your second piece of cardboard.  Cut out the back panel using the craft knife.

NOTE: You'll be making a "sandwich" from the cardboard pieces, so be sure to keep track of which side is the inside and which will be the front or back painted side of each piece.

Step 2
Draw Design Details

Using the pencil, sketch in the basic details of  your design on the front and back costume panels. Next, trace over the pencil lines with permanent marker to create painting guide lines on the costume panels.

Step 3
Prepare Work Area

Protect a large table or floor with plastic drop cloth or newspapers (or if the weather is nice, you can work outdoors). Lay out both panels on the protected area and you're ready to paint.

Step 4
Paint Front and Back Panels

This is the fun part for the children!

Pour small amounts of paint into recycled foam trays, paper plates or other recycled containers. Provide a few flat plates to use for color mixing and blending. Paint the outlined areas of the design in your desired colors. Allow paint to dry thoroughly, then add any detail lines or color glazes. Allow final paint coats to dry for several hours.

Step 5
Assemble the Costume Panels

The "sandwich" costume needs to hang on the child's shoulders and fasten loosely near the waistline.

Hold the front panel up against the child's chest to determine where to position the shoulder straps. Mark lightly with pencil at the top of the front and back panels at mid-shoulder.

Lay panels flat on cutting surface. Using the pencil lines as a guide cut two slits about an inch wide and an inch from the top edges on both the front and back costume panels.

Match the front and back panesl together with insides facing each other. Thread a length of ribbon or a single shoelace through the slits from front to back at each shoulder. Leave a gap of ribbon about 4 inches wide between the panels. Tie the ends of each shoulder stra[ loosely in a bow and try on child.   Adjust the shoulder straps as needed to allow panels to hang freely in front and back.

Following the same procedure as for the shoulder straps mark the position for the waistline ties.

Remove costume from child and cut slits in back and front panels for the waistline ties. Thread ribbon or shoe laces through from front to back leaving a gap to allow costume to slip over child's head. Slip costume over child's head and tie at waistline, leaving enough slack so child can walk without costume binding.

Step 6
Costume Accessories

Dress your child in simple solid color shirt and pants or leggings that will complement the costume design. You might also make an eye mask or use face paint to add more interest. Or, you can have your child wear a hat to accent the costume.

For example, if you create a rainbow costume, dress the child in blue pants and white shirt. Make a sun mask  or hat from a pie plate.

More DIY Costume Tips

More Easy Costume Fun: Instant Masks


If you really don't have time to make a costume, try just making a mask. Paper masks are quick and easy to craft. Many printable instant masks are available online, or you can create a quick mask from a photo, drawing or even a paper plate.

Materials & Supplies

  • 2 clean corrugated cardboard sheets approximately 18 inches x 24 inches, cut from a large shipping carton OR
  • 2 sheets of foam core craft board from art supply store
  • Acrylic paints in various colors
  • Paint brush, sponge
  • Pie pans or foam trays for mixing paint colors
  • 1 to 2 yards 1-inch wide sturdy ribbon or 4 strong shoe laces
  • Pencil, permanent marker
  • Craft knife or heavy scissors
  • Newspapers or drop cloth to protect work area
  • Disposable rubber gloves, apron or old shirt

Comments (1 to 2 of 2)

Marie S
Oct 25, 09 at 05:01 PM
I like this layout also. Very well detailed instructions for making a Halloween costume. Poutine
Tony Payne
Jun 04, 09 at 04:46 PM
Looks nice, I like the layout. This style with a wider left column would probably work better for my Zones too.

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