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This is how I made my Flynn Rider costume for a local fairytale ball I recently attended. Flynn is the roguish hero from Disney's Tangled, a new twist on the tale of Rapunzel. I found this handy resource that gave me all the details that were needed:
http://www.squidoo.com/flynn-rider-costume-tangled
They say the vest is made out of some sort of leather, but I chose some blueish-teal 16 WPI corduroy partly because I love corduroy, and partly because it was on sale. For the lining I chose some navy quilted poplin to give it a bit of structure and insulation in case I ever need it for a chilly Halloween party or something. Perhaps not the best choice for an indoor dance party, it got pretty warm wearing a long shirt & trousers as well. 

Ingredients: 
  • an old T-shirt for the pattern
  • ~1½ yards of corduroy
  • ~1½ yards of quilted poplin
  • a bit of iron-on interfacing
  • suitable thread
  • #8 wire. A bit of a kiwi specialty, a wire coat hanger will do fine as well
  • bronze bluejean rivets

All the pictures of animated characters are the property of Disney®
 
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Step 1: Pattern making

First try on your T-shirt, we're going to cut it up and turn it into a pattern for the vest. Pin it up the sides so it fits the way you want. Try to approximate the sleeve seams with some chalk, my shoulders aren't very wide so I just traced the existing seams in the T-shirt, only a couple of inches in so they lined up with the pins up the side. Put a mark where your belt buckle usually sits, then take it off and trace the side lines where the pins are. Also draw a centerline and put in the V on the chest where the vest material changes direction. 

Remove the pins, and cut off the sides & sleeves. Then separate the front pattern from the back by cutting along the seams at the tops of the shoulders. Now you can cut the front in half along the center. Lay the front halves on top of one another, wrong sides together, and cut the top from the bottom along the V line. Put an arrow across each upper front pattern piece indicating the grain direction of the fabric, as indicated in the photos from the link.

For the back pattern, you'll need to cut the yoke which goes from sleeve seam to sleeve seam with a little dip in the middle. Freehand the line in chalk, decide which half looks better, fold it in half, and cut along the line so both halves are the same. 
jmann6 says: Jan 7, 2012. 9:09 PM
I was looking all over for a pattern that would match a costume I'm making for my boyfriend of his rogue character. The pattern for a doublet was out of stock, so after searching all over for something, I stumbled across this and it seemed perfect. I was actually looking to NOT have to make stuff up, but because of your excellent descriptions and the pictures posted, it really wasn't at all difficult to tailor it to what I needed (not that the vests were terribly different).

It turned out really well, I think, thanks to your instructable!

I'm glad I wasn't the only one listening to proper mood music while working. If Grace Potter is a family friend, pass on the word that I LOVE the song!
mbyington says: Oct 28, 2011. 12:13 PM
Thank you so much for these instructions! my 3 yr old wanted to be Flynn Rider this year for halloween and his vest turned out great! I will post pics later. Thanks again!!
andrew.spencer.2 (author) says: Oct 15, 2011. 7:55 PM
It took me the better part of a week's worth of free time to figure out, but with these instructions you could probably churn one out in a weekend. Be sure to post some photos when you're done, best of luck!
swilhite says: Oct 15, 2011. 6:52 PM
About how long did it take to put it together? It looks pretty amazing and I've been looking for instructions for this for my boyfriend. We want to dress up as Rupunzel and Flynn for Halloween this year. :)
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