How to Make a Low Budget Han Solo Halloween Costume





Introduction: How to Make a Low Budget Han Solo Halloween Costume

My co worker needed a last minute Halloween costume so after taking an inventory of useful items I helped him make this costume the night before Halloween- we did it in my freezing cold garage in about four hours.
It was so cold the glue would instantly solidify when it came out of the hot glue gun.....

Step 1: Materials

For the clothing you'll need some dark brown pants, a blue jacket (or blue vest- this can also be made from a blue shirt- the miltary BDU style works best), a white pull over shirt and some yellow felt. We used some old combat boots because that's what he had but some cheap rubber rainboots would work just as well.

For the blaster you'll need a couple of funnels, a few wood dowels, some 1/8" hardboard, a small diameter tube (brass or whatever), a small PVCconnector and a 1x6 wood board as well as a can of black spray paint and some glue- epoxy is best.

For the gun belt you'll need some thin aluminum sheet, some 1/8" hardboard, some rivet style snaps and some brown vinyl.

You'll also need a hot glue gun, a rivet gun and a few wood screws.

Step 2: Clothing

All that really needs to be done here is to cut a small vertical slit in the white shirt (unless it already has one) and cut the yellow felt into small rectangles and glue them onto the sides of the pant legs with ta hot glue gun. Clothing done!

Step 3: Blaster

To make the blaster first cut the outline of the gun shape from the piece of 1x6 wood. Then carve the relieved areas around the trigger and grip with a dremel. Now make the gun barrel from a wood dowel and glue it on top of the gun body. Now cut two pieces of 1/8" hardboard and glue them on each side of the barrel on top of the gun body. Glue the PVC coupling on the end of the gun barrel and glue a cut section from a funnel on the other end of the coupling.

Now make the scope from a couple of wood dowels and another funnel section an glue a small diameter tube onto the end of the scope. Make the scope bracket from a piece of 1/8" hardboard and a dowel and secure it to the blaster with three screws. Paint it black!

Step 4: Making the Belt/holster

First make the buckles from thin aluminum sheet and glue some hardboard to the back of the buckles. One buckle gets three screws in it as shown- this is the front buckle. The second buckle get three screws- two of them go directly through the belt- this is the back buckle.

Make the belt from vinyl. Now make the belt ends (three of them) from thin aluminum sheet as shown. They are designed to slide over the screws. These get riveted onto the ends of the belt and holster.

To make the holster lay the blaster down and cut the vinyl around it to get the shape right and then glue it together with the hot glue gun. Now rivet on the belt ends. Make a leg strap and a holster strap from vinyl and put snaps on them.

Connect everything together by slipping the belt ends onto the buckles- that's it! There are some pouches that are on the movie belt as well as a "droid caller" but I left those off in the interest of time and cost.



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    Very cool! For throwing it together in 4 hours this is very well done! Nice job on the blaster as well. Siple yet effective!

    Have you seen Star Wars The Force Awakens Han Solo Brown Leather Jacket?

    How come no one noticed Han has no sleeves on his black jacket?

    Because in Empire Han wears a jacket. Just Google Han ESB jacket.

    okay first of all, since im good with star wars, if you want han solo in episode 4 then you need a (black) vest, works with military shirt like said, also the pants were Navy with the yellow stripe on the side and the boots were like civil war cavalry boots not combat,and the his gun is the broomhandle / mauser and it needs a scope on top!

    As I have stated before, accuracy was not a great concern (in fact not at all!)- we had to use what we could find in very short time and make it work. When you only have a few hours you have to compromise. :) The blaster does have a scope in the correct position- take a closer look. All DL-44 blasters used side mount scopes. The DL-44 that was used in ANH had a side mounted long scope but there were two hero versions- the original and "Greedo Killer" version. The GK version has a different front grill and flash suppressor and a different scope mount if memory serves... The GK version was used while filming in the U.S. and the original version was used in Lndon. ESB and ROTJ both used side mounted scopes but they were of a different shorter design than that of ANH. The ROTJ blasters are easily identifiable by the pistons cast into the side of the blaster. There were also differences between the hero and stunt props. The blaster I made has a scope similar to an ESB version. I've been a RPF member since 2003 so I know how to make a screen accurate Solo costume no matter which version you prefer. There are lots of decent reference images here:

    You certinly know your star wars!

    I love this ....completely and utterly love this.....

    Thanks! We had a lot of fun on Halloween that year. :)

    Your welcome and idont under stand all thw critism who cares if the pant legs are wrong s still han solo