DIY Video Tutorial - Kids Flying Astronaut Halloween Costume

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

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

Here's what you'll need and how to make it:

Supplies:

• space suit
• elastic
• duck tape
• hot glue gun
• X-ACTO knife
• pool noodle
• orange fabric
• red fabric
• yellow fabric

Video Instructions:

Step-by-step instructions:

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.

Then, we cut triangles from yellow, red and orange fabric (mostly from scrap fabric and old t-shirts). Add them to the skirt using a hot glue gun – starting from the bottom and moving up. Note, triangle pieces toward bottom of skirt are smaller and gradually get larger toward the top.

For the rocket pack, we used cardboard, hot glue and duck 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.

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

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

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

This is the space suit we bought. I would highly recommend getting this because it comes with the light weight boots that work great for the costume. 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

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

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

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

Insert and glue/tape from the front and behind.

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

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…

Put on flame skirt

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

Buckle the belt.

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.

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.

And…BLAST OFF!

We can’t get over how real this looks!

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 #CREATEmore and 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 in the comments section!

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

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

If you make your own versions we'd love to see! Tag #IZZAROOcostumes for a chance to be featured on our website.

See our past Halloween costumes for more fun ideas.

To see some of our fun video tutorials, check out our YouTube channel.

If you love to create like me, you'll love our collection of Create More shirts. 10% of net profits will benefit organizations that empower underprivileged youth. Learn more about our mission to Be The Good.