How to Make a Realistic Astronaut Costume

Written by victoria smoothens
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How to Make a Realistic Astronaut Costume
Construct the core of a child's astronaut costume with clothes you have already lying around the house. (astronaut image by Ewe Degiampietro from

Halloween should be a time for kids to use their creativity and imagination without causing parents to spend ludicrous amounts of money on a professionally manufactured costume. Constructing a realistic astronaut costume for your child on Halloween does not have to entail buying a helmet or space pack from a costume store. Your child will look and feel like a genuine astronaut in an affordable, entirely homemade costume when you follow these tips.

Skill level:

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Things you need

  • White or orange body suit
  • White or orange overalls
  • White or orange turtleneck (optional)
  • White or orange sweatpants (optional)
  • Rain boots
  • Orange and silver spray paint
  • NASA patches (optional)
  • Coloured markers
  • Coloured poster board
  • Scissors
  • Glue gun
  • Iron (optional)
  • 2-liter soda bottles (2)
  • Milk jugs (2) (optional)
  • White duct tape
  • Plastic utensil tray
  • Adhesive-backed Velcro
  • Pencil
  • Plastic bucket
  • Hammer
  • Nail
  • Wire cutters
  • Foam board
  • Dish towel
  • Mirrors and reflectors
  • Glow-in-the-dark stickers

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  1. 1

    Select a white or orange body suit and overalls, or a turtleneck and sweatpants. Spray paint a pair of old rain boots orange. Purchase NASA patches from the NASA History Division website (see Resources). Adhere the patches to each sleeve of the chosen clothing with a glue gun or iron. Alternatively, draw NASA patches with coloured markers on coloured poster board, cut out, and attach with a glue gun.

  2. 2

    Wash two empty 2-liter soda bottles and spray them with quick-drying silver spray to serve as air tanks. Alternatively, wash two milk jugs and wrap white duct tape around them to achieve realistic colouring and bind them to one another. Find a plastic utility tray to serve as a control panel.

  3. 3

    Place a 17-inch strip of duct tape sticky side up on the table. Attach another 17-inch strip of duct tape on top of it with the sticky side facing down. Repeat this process to create four separate straps. Attach the straps to the middle of the bottles and plastic utensil tray with duct tape or adhesive-backed Velcro to serve as suspenders. Have the child model the pack. Adjust the straps to fit the child's height if necessary by trimming or rolling the ends of the straps.

  4. 4

    Duct tape the other two duct tape straps to the sides of the bottles to serve as side bindings. Have the child model the pack again. Adjust the straps to fit the child's body if necessary by trimming or rolling the ends of the straps. Attach the other end of the straps to the utensil tray with duct tape or adhesive-backed Velcro.

  5. 5

    Draw an oval face opening that fits your child's face in pencil on the plastic bucket-- minimal measurements of 7 inches wide by 5 inches high are recommended. Hammer a nail into the centre of the oval face opening to create a small hole. Using the hole as a starting point, cut the oval out of the bucket with wire cutters.

  6. 6

    Cut out two foam-board rectangles 2 inches wide by 9 inches high to serve as helmet braces. Cut the lower corners into a rounded shape so they don't poke the child's back. Attach the tops of the braces to the lower inside of the helmet with duct tape. When the child puts the helmet on, the foam braces will slide between his back and the space pack.

  7. 7

    Wrap a rolled up dish towel around the child's head so that it forms a ring. Tape the ring closed. Remove the towel from the child's head and tape it to the top inside of the helmet to serve as a buffer against the helmet.

  8. 8

    Attach mirrors and reflectors to the space pack with adhesive-backed Velcro. Attach glow-in-the-dark stickers to the costume clothing.

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