An aeroplane costume is an ideal costume for a young child and one that can be created from items found in your own home or with a few small purchases at a craft store. Get your child involved and make it an arts and crafts activity that can be worked on together. The colour choices for the aeroplane can vary, and it being a costume, can be more colourful and bright than typically seen on planes. Incorporate the child's favourite colours to add a bit of his personality to the costume.
Choose a box that is proportionate to the child's size. The box should fit over the child's torso. This will likely be at least two feet wide and three feet tall.
Cut the bottom flaps off the box and cut a square to fit his head through in the top. The square for the head should not be so large that it falls past his shoulders; the box should rest comfortably on his shoulder blades. Cut round or square holes in the sides for his arms to fit through.
Glue an approximately one foot long by six inch wide rectangle of cardboard onto the top of the box, on either side of the head opening. These will be the aeroplane wings. The exact size of these cardboard pieces will vary depending on the size of the main box and thus the child within it. Ideally, the cardboard strips will hang over the shoulder blade area of the main box by about five inches.
Cut a square piece of cardboard approximately a foot tall and a foot wide. This will be the tail piece. Fold a one-inch crease in the bottom of the square. Glue the bottom of this flap straight back on the back of the box behind the head cut-out so the square stands straight up.
Cut two oblong pieces of cardboard approximately three inches shorter than the diagonal length of the front of the main box. Glue these criss-crossing across the front of the box as propellers. Paint the entire box including all components to the desired colour scheme and design (see References for finished product).
For added detail, wrap a colourful scarf around the neck of the costume wearer and place goggles on his head to give the look of an old-fashioned pilot.