I couldn't pass this up.
You can buy a similar costume online for $100, but where's the fun in that? This only cost around $30. Plus a lot of hours of course, but it was worth it.
(That's me with my best attempt at an unhappy Ralphie-scowl.)
Step 2: Pattern
But making up patterns isn't what most people would consider fun, so I've included a PDF with scale drawings on graph paper of all the pattern pieces, along with some construction details that might be helpful. You'll still have to lay everything out full scale, but I figured someone who was willing to do the work would find it useful.
The body section is just a big floppy jumpsuit, so I didn't need a terribly precise pattern for it. The hood pattern, however, took a little more effort and required some trial and error before I came up with the right shape.
This pattern is designed for anyone around 6 feet or so, and upwards of 200 pounds. Skinny people can adjust it accordingly. Or eat more.
Step 3: Body and sleeves
The two body pieces are joined with a seam along the back, down to the crotch.
The two sides of each sleeve are sewed together along the bottom. The half-sewn sleeves are pinned to, and then sewed into the sleeve openings on the body section. (This process is upside down to how most sleeves are attached to shirts.)
A seam is made across the tops of the sleeves and each shoulder.