Han Solo Costume

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Introduction: Han Solo Costume

Halloween Easy Costumes Contest

Finalist in the
Halloween Easy Costumes Contest

I've been a long time Star Wars fan and one day realized that I didn't have to only cosplay as female characters. Why not do a male character? So I decided to create a female version of Han Solo. 


Step 1: Han Solo Shirt

In my opinion, the key to a good Han Solo shirt is finding the right material. Remember that Star Wars was made in 1977 so there were a lot more polyester shirts back then. Han Solo wears an off-white, almost beige, 3/4 sleeve loose v-neck shirt with a half-collar. I initially checked eBay and some thrift stores, and even tried to make my own. I ended up getting pretty lucky and found a vintage polyester shirt with puffy sleeves and a crazy '70s collar. I took that shirt and modified the sleeves and tucked in the collar to be more "normal". This is what I ended up with.

Step 2: Han Solo Vest

I knew that the key to a convincing vest was finding the right type of material. I decided to hit up some thrift shops and just see what was out there. Specifically, I was looking for something in a stiff black fabric that would give it the rugged and outdoorsy look – maybe something like canvas or khaki. I ended up finding a great peacoat and decided to reconstruct that as a vest.

Once removing all the buttons, cutting off the collar and the sleeves, I then proceeded to slim it down to look more like a vest. Since the peacoat was originally flared out at the waist and was double-breasted in front, I had to pin everything to look more straight. 

I used all of the leftover fabric from the sleeves of the peacoat to strategically plan out the rest of the pockets. I started with the front pockets by roughly cutting some rectangles, tucking in the edges and sewing them down 3 sides at a time. I created the flaps by also just sewing the seams and then pinning them above the pockets and sewing the top edge down. Han’s vest has 3 cargo style pockets and one curved patch pocket on his top right.

By the time I got around to the pockets in the back of the vest, I was pretty low on fabric so  I had to make his back lower pocket slightly smaller than it probably should have been. And as you can see, I only have 3 slots in the upper back instead of 4.

Step 3: Han Solo Pants

For the pants, I shopped around for the perfect pair of navy pants. I ended up buying some uniform pants since they had a very simple design. I knew I didn’t have the right machine to embroider red bloodstripes all the way down the leg so I decided to buy some red seam binding (about 3/4″ wide) and draw the stripes on the strip. I marked about every half inch down the red strip allowing about 1/16″ room for the thickness of the lines. This was pretty tedious, but I’m sure it beats embroidering! I decided to use a blue permanent marker (not a Sharpie because it runs funny). Make sure to test this out first to see if the ink will run!

And since I was wearing long boots, I knew I didn’t have to do the entire pant leg. In fact, I decided to cut the pants up to my calves just to keep my legs cooler and prevent having to stuff my pants in the boots.

And I really hate glue-gunning fabric, but there was no way I was going to take apart all the seams and sew this on. If you can find the iron-on version of this seam tape, definitely buy that one! Otherwise, you’ll have to glue gun everything like I did here.

Step 4: Han Solo Boots

For the boots, I shopped around for a while to find the perfect pair. When looking for boots, make sure they are:

-black
-simple in style
-pull up style if you can (no zipper)

Some suggestions here.

Stay tuned... I will be posting a tutorial on Han Solo accessories (belt, holster, gun) soon!

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    34 Comments

    Wonderful! Thanks!

    hey great costume, but what about the accessories? specially the belt :c The Force Awakens is coming and I wanna make this for my girlfriend c: as a surprise cause she told me she wanted to dress up but didnt know go as, except darth vader but a good one its hard to get

    Love the idea of the coat. Attempting the same, so far so good.

    quite interesting...'han solo' is my favorite character in starwars, it arkward..because girl turn to be 'han solo', maybe with some name..maybe, 'hana solo' perhap

    How do you make the belt/holster?! That's the most important part!

    Cute :P

    I must know how you build your solo accessories! They look fantastic!

    This is fantastic work, incredibly accurate, especially considering how inexpensive it is! Looking forward to seeing your tutorial for the belt!

    Oh please take me away on your Milennium Falcon!