Astronaut Costume





Introduction: Astronaut Costume

Autodesk Employee Halloween Contest

Finalist in the
Autodesk Employee Halloween Contest

I love space. So I decided to make a space suit** for halloween. It was super fun to make, and relatively inexpensive.

I was able to make it out of things I had lying around from old projects. I imagine that if any maker-type wants to put this together, that already has a stock of supplies will only have to spend 20 or so dollars to complete this project.


Step 1: Gather Materials

For Helmet:
  • Wood Glue
  • Water
  • Really round balloon (available at party stores)
  • Phonebook
  • Wood Filler
  • LEDs
  • 9V Battery
  • 9V Battery Clip
  • PCB
  • wire
  • Hot Glue Sticks
  • White Acrylic Paint
  • Silver Spray Paint
For Space Suit:
  • Painter Suit
  • White Satin
  • Silver Lame
  • Interfacing
  • Felt
  • Hot Glue Sticks
  • Thread
  • Stir Stick
  • Scissors
  • Gloves
  • Razor Blade
  • Sand Paper (80 Grit and 150 Grit)
  • Soldering Iron
  • Wire Snips
  • Wire Strippers
  • Paint Brush
  • Bowl
  • Sewing Machine
  • Serger
  • Glue Gun
The hardest thing to find for this project was a phonebook.

Step 2: Blow Up Balloon, Mix Glue, and Cut Strips.

If you are using wood glue, you can use a 1:1 ration of water to glue, and coat your paper strips with them before you apply them to the balloon.

Step 3: Paper Mache!

There are lots of really good Instructables on how to paper mache, after a little research I believed I was ready to begin. I dipped each strip into my gluey water and then applied it to the balloon. I think I ended up applying six layers of paper, and it took....... a long time.

When I was done applying the strips, I made a slightly thicker glue/water solution and brushed it over the entire surface of the sphere.

Then, walk away. This guy took two days to dry.

Step 4:

Using a razorblade, I pierced the balloon. I cut a hole big enough for my head, and then separated the balloon from the paper.i

Step 5: Fill, Sand, and Paint!

After the helmet had been fit, I had to remove some of the large wrinkles from the sphere - so I used some wood filler! I sanded the entire sphere with 80 grit sandpaper so that the wood-filler would bond to the sphere.

Again, wearing gloves, I squeezed the wood filler from the tube and smoothed it into the cracks. It took about two hours to dry.

I then re-sanded the entire helmet with 150 grit sand paper.

Step 6: Painting and Cutting.

I painted the outside of the helmet with white acrylic paint. It took about 30 minutes to dry.

I then traced out a  basic shape around the sphere that would be the helmet's opening. Using the razor blade, I cut the opening out.

Using some bailing wire, and some masking tape, I reinforced the cut edge of the helmet, so that it wouldn't slump on my head. I then sprayed the inside of the sphere with silver spray paint.

Step 7: Add LEDs to the Helmet.

I plugged in the hot glue gun, and the soldering iron.

I soldered 4 LEDs to eachother, in preparation to make parralel series that could be powered by a 9V battery. Then, I glued down the LED series, and ran wires all through the helmet to one PCB.

I plugged in a 9V battery, and it worked! Onto the suit!

Step 8: The Suit!

This part is pretty fun. It's great because I was able to imagine whatever I wanted to put on to the suit. I based it of a really big painters suit that was about 8 bucks from the hardware store.

I made up some elbow and knee patches out of silver lame and interfacing, making rippled waves with the sewing machine, then cleaning up the edges with a serger. I had to open the legs and the arms of the suit to sew down the patches.

Step 9: Go to Space.

I realized that the more bulky this suit looked, and the more panels I added the more authentic it seemed. I want to grow the costume to  be appropriate for other festivals and events where I could sport an astronaut costume.

I paired the suit with my super busted snowboard boots, and they looked great. The paper suits are a bit flimsy, but a great base for this costume. 



    • Paper Contest 2018

      Paper Contest 2018
    • Science of Cooking

      Science of Cooking
    • Pro Tips Challenge

      Pro Tips Challenge

    We have a be nice policy.
    Please be positive and constructive.




    I made his helmet based on yours!


    tyvm for the helmet guide, should be very useful. I've already bought white overalls (boiler suit) and had been planning to use an outdoor lighting post topper, but too expensive and time consuming, especially when shipping factored in. All the 'detail' will done with EL wire.

    I am going to use this method but instead im going to make a Koro Sensei head for a cosplay!!! Thanks so much!!!

    I'm curious about the bailing wire. Was the helmet not stiff enough to hold its shape when you finished? Did making the cut out compromise the integrity of the shape? Would love a little more information about why you thought it was necessary.

    It did bow a little, but the wire helped. If I had more layers of paper, it may not have bowed.

    If I was to do it all again, I would just fiberglass the whole helmet.

    Hmm, I see. I've got the ball rolling with paper mache but maybe next I'll learn how to do fiberglass! Thanks!

    U could vacuum form a shield for the helmet

    Thanks it was great idea and easy to make costume. I made a small changes and it was areal blast at the party