Although he never speaks, Chewbacca is a favourite of many Star Wars fans for his comical grunts and growls, and his gentle giant demeanour. Han Solo's partner and best friend, Chewbacca follows him and Luke Skywalker as they battle the evil Empire in all three of the original Star Wars movies. Although it may appear difficult, a Chewbacca mask is actually very easy to make, and it is the most important part of a complete Chewbacca costume.
Paint over a plastic Halloween mask. Paint the centre of the mask between the eyes and nose using brown acrylic paint. Paint a black triangle for the nose.
Cut off the strands of fake hair from a brown wig using a pair of scissors. Cut the strands so that they are around 2 to 3 inches long.
Bunch a few centimetres of the hairs together and dab a bit of glue onto the end using a glue gun. Be sure to let the glue gun warm up for 10 minutes before using it, so that the glue will be soft enough. Stick the hairs around the mask so that they radiate out from the centre. Let the glue dry.
Dollar stores are a great place to find cheap Halloween masks you can use for the Chewbacca mask.