Introduction: Make a Wookiee Cushion With Sound Effects

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Turn a rectangle of fake fur into a Star Wars character cushion. A classic Curiosity Hacked open lab project that kids can do, perfect for May the 4th :)

Step 1: Assemble the Materials

The following materials can be found at most fabric or craft stores:
  • One piece of wookiee-style brown fur, approx.  14" x 9"
  • Brown felt:
    • cut one strip 9" x 1-1/2", for Chewbacca's toolbelt
    • cut a small circle or teardrop shape, for Chewbacca's nose
  • Gray or white felt, cut into squares and rectangles, approx. 1 x 1 and 1 x 1-1/2
  • Two black buttons approx. 1/2" to  3/4" in diameter
  • Pillow stuffing foam one small bag.
You will also need a few tools:
  • Scissors
  • Needle
  • Black thread
  • Glue gun (optional) 

Step 2: Sew the Features and the Toolbelt

Lay the strip of brown felt on the table and arrange the white/gray felt rectangles on top of it.  Sew these in place.  (If you're in a rush you can attach them with a glue gun - that's what we do during Open Lab).  Set the toolbelt aside.

Fold the fur piece in half with the fur facing out.  This is how large the final Wookiee will be. Position the buttons (the eyes) where you want them to go, and holding them (or pinning them) in place,  unfold the fur and sew the buttons on.  Do the same thing for the circle of felt (the nose).

Now lay the fur out and arrange the toolbelt so it goes across Chewbacca's "body" from his left shoulder to his right hip.  Sew both ends of the toolbelt in place (you can stitch along the whole thing if you want, but you don't need to).

Step 3: Program the Sound Player

We found some inexpensive sound players at Sound Expression Greetings:  push-button sound player;  heart-shaped squeeze button sound player.   We've also tried this larger, slightly more expensive but easier to program push-button player.

Step 4: Stitch the Edges of the Cushion Together

Fold the fur in half with the fur on the inside, and stitch the top and side together using a blanket stich. Leave the bottom open and tie off (knot) the thread.

Sew the pressure tab for the sound player behind Chewbacca's nose -- or his belly button, or wherever you want -- with the pressure button facing down into the fabric. Do not sew through the electrical wires! If there aren't any holes in the pressure button, glue a piece of fabric to the back of it. For an example of this see the picture below with the orange fur.

Now turn the piece right-side out, so the fur is on the outside. Stuff the Wookiee Cushion with pillow foam, and use a blanket stitch to sew the bottom seam shut.