Picture of Astronaut Costume
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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.

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Step 1: Gather Materials

Picture of 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.

Picture of 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!

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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:

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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
glitterbuggg5 months ago

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.

audreyobscura (author)  glitterbuggg5 months ago

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!

DE4D POOL1 year ago
U could vacuum form a shield for the helmet
william_w2 years ago
Thanks it was great idea and easy to make costume. I made a small changes and it was areal blast at the party
audreyobscura (author)  william_w1 year ago
Thanks again
i want to wear this in a landscape made of cheese :D yayyyy!!!
So good.
sanid1692 years ago
I made a similar suit myself this year, but I decorated the suit to match Felix Baumgartner's suit.. =) I was going to put a slight twist to it though.. Going to,., because I found out my job wouldn't allow it this year... but anyhow.. I was going to put a nice big brown stain on the backside... =) So I got a suit but no where to wear it!
This is just awesome and I'm so glad you made a space gif for it!!!
j9mosely2 years ago
Great space suit!

I made a very similar one in 1973. I blew up a balloon and covered it with plaster, then pulled the balloon out and used the plaster mold to lay up a fiberglass helmet. I cut a big hole in it and bolted in a motorcycle bubble-style face plate, filled the gaps with body putty, sanded and painted it. They didn't have Tyvek painter's suits back then, but I found a silly exercise suit made of mylar (you're supposed to lose weight by excessive sweating) that worked pretty well. I wore welder's gloves and some old rain boots with it.

When I wore it in public, I would take the helmet off and say "One small step for a woman -- one giant step for womankind!"
angelabchua2 years ago
i LOVE this!!!!
waterbaby2 years ago
Out of this world!!! (Sorry, just had to do it....) So creative and fun and very well done, plus bering inexpensive, relatively easy, AND customizable!
audreyobscura (author)  waterbaby2 years ago
mamalove2 years ago
x infinity

This is fabulous.