Introduction: Star Wars Rey Costume With Props

This is a Star Wars Rey costume I made for my daughter, complete with a bunch of accessories.

The techniques I used to make this could easily be scaled for a person of any size.

Step 1: Materials

I raided all of my fabric bins and pulled out anything that might be useful.

I'm a hoarder when it comes to fabric and supplies for making stuff, so a lot of what I needed I already had on hand. Here's a list of most of the materials used for this project:

  • A "Onesie"-style toddler body suit for the shirt
  • A couple small pieces of an old gray sheet became Rey's pants
  • Fake leather from an old suitcase became all the various leathery bits
  • Brown corduroy was used for Rey's satchel/hip bag
  • Natural-colored cotton was used for her shoulder sashes and arm wraps (this was purchased)
  • Furry fabric and old sneakers were used to make the boots (purchased)
  • A wooden dowel and miscellaneous bits of stuff were used for Rey's "Quarterstaff"
  • Instant coffee, bags of black tea, and fabric dye for altering colors of fabric

And the tools I used:

  • Sewing machine
  • Serger - I survived for years without one, but just picked up one at Walmart. It works well and was less than $200.
  • Glue gun - I got this high temp glue gun a while ago and love it.
  • Cutting mat and all the typical crafting tools (hobby knife, scissors, etc.)

Step 2: Dying Fabric

The natural color of the cotton I had purchased for Rey's shoulder sashes and arm wraps wasn't quite the color I was after. I wanted it to be more greyish-ish.

I played around with various dyeing techniques to see what I could come up with. After some experimenting, this is what I ended up doing to about two square yards of cotton:

  • Washed the fabric on hot cycle a couple of times to shrink and loosen up the fibers
  • Mixed about 3 table spoons of Pearl Grey Rit dye into 2 gallons of very hot (but not boiling) water in a bucket
  • Stirred the fabric around in this for about 5 minutes, and then rinsed it under cold water until the water ran clear
  • Mixed about 1 cup of instant coffee into 2 gallons of very hot water in another bucket
  • Stirred the now-lightly-grey fabric around in the coffee and rinsed, just as was done with the grey dye
  • Dried the fabric in the dryer and then ironed it flat

Step 3: Shoulder Sashes

For the shoulder sashes, I wanted them to be somewhat permanently wrinkled. Otherwise we'd be fussing with trying to make the wrinkles look right whenever my daughter wears this costume.

The details of the process I used are outlined in the photo notes.

Step 4: Shirt

The onesie I used for this was stark white, and I wanted it to be just slightly greyish.

To achieve this color, I dyed the shirt in one gallon of hot water with one table spoon of grey dye. I stirred it around for a few minutes and then rinsed it thoroughly. This created a very subtle off-white color.

The bottom snaps of the onesie were trimmed off to make it into a plain shirt.

Step 5: Pants

I happened to have an old sheet that was the exact color I wanted for Rey's pants.

Using a pair of my daughter's pajamas I made a rough pattern to use to make these pants. See notes in photos for details.

Step 6: Hip Bag/satchel

I made a hip bag to look like Rey's out of some old corduroy with various bits of things added on for detail.

Step 7: Belt

The belt was made with fake leather, hot glue, and some cotton string.

Step 8: Cuff Bracelet

A simple cuff bracelet was made with fake leather.

Step 9: Arm Wraps

The arm wraps were made from strips of cotton that were 1 1/4" wide by about 60" long. These were serged along the edges to keep them from fraying.

When worn, these are wrapped in place and then held on with safety pins.

Step 10: Quarterstaff

I wanted to make a very simple staff that just evoked the style of Rey's quarterstaff.

It actually turned out better than I had hoped for!

How this was done is outlined with lots of notes in the photos here in this step, as well as the next.

Step 11: Finish Details for Rey's Quarterstaff

The quarterstaff was painted and various colors were added to create depth and a bit of weathering.

Step 12: Boots

The boots were made by simply hot gluing pieces of wooly fabric onto an old pair of thrift store sneakers. I sent them through the wash first, however. Who knows what nasty foot germs the previous kid had!

Little details were added with fake leather and pieces of yarn.

Step 13: Done!

This Rey costume is not "movie-accurate" or anything, but I was happy with the ratio of details I was able to include for the time and effort I put in.

Thank you for taking a look. I hope this will help you with a similar project!

As always, thoughts and feedback are enjoyed and appreciated :)


Astuces de Trente Secondes- made it! (author)2017-03-16


coolcrafter101 made it! (author)2016-12-14

Oh my gosh that little girl is so cute!

AndreG87 made it! (author)2016-10-04

Message me, I'd like to pay you to make one for may 27 month daughter!

HollyMann made it! (author)2016-09-15

It turned out amazing...she is absolutely adorable beyond words...

jegatheesan.soundarapandian made it! (author)2016-08-15

Very Very nice Costume... and Very Cute Baby

ChrisD142 made it! (author)2016-06-30

my gosh, you Are Talented !! Well Done !

briarmoon7 made it! (author)2016-06-09

Love the fact that it was made without a purchased pattern. I made all my kids costumes from scraps, thrift store stuff, etc. Your daughter will remember the fun she had wearing it.

seamster made it! (author)seamster2016-06-09


I've never used a purchased pattern for any of my sewing projects - I just kind of like cobbling stuff together and figuring it out as I go! I guess it's just my defiant "I'm not asking for directions" man-trait ;)

kylegilbert made it! (author)2016-05-19

Man, you've created so many cool things on here, and this is one of my favorites!

seamster made it! (author)seamster2016-05-20

Hey, thank you very much!

You've shared some fantastic stuff yourself - I love several of your projects! : )

Lineakat made it! (author)2016-05-08

this is so cute!

MikaelaHolmes made it! (author)2016-05-07

This is so good!!!! So well done, so adorable, so much attention to detail! Well played sir :)

seamster made it! (author)seamster2016-05-07

Thanks Mikaela!

deluges made it! (author)2016-05-07

What a haircut!

seamster made it! (author)seamster2016-05-07

It was pulled back into 3 looped ponytails, just like Rey from the movie (see 2nd photo in intro). The loose fly-away strands make her haircut look more wild than it really is, I promise ;)

chienline made it! (author)2016-05-06

One cute baby Rey. What an awesome encyclopedia of Starwars you have on your desk :D

tinaciousz made it! (author)2016-05-06

she looks just like you :)

Ygdrasil made it! (author)2016-05-06

Awesome !

MarceloM37 made it! (author)2016-05-06

perfeito adorei

Jedi_zombie85 made it! (author)2016-05-06

LOL epic nice work

kylegilbert made it! (author)2016-05-05

Very nicely done! :)

audreyobscura made it! (author)2016-05-05

GAH! So good! Really nailed this one. Took some notes on your prop making technique!

seamster made it! (author)seamster2016-05-05


I got a real kick out of how the staff turned out. I've never done much in the way of prop making, but now I want to try something a little more detailed and elaborate. It was fun! :)

Natalina made it! (author)2016-05-05

Cuteness overload!!

asergeeva made it! (author)2016-05-05

Beyond words - SO ADORABLE!

reginaann made it! (author)2016-05-05

Adorable, and very well done!!

Carleyy made it! (author)2016-05-05

Sam, your daughter is so cute!!

BKLaRue made it! (author)2016-05-05

This is soooo cute!!

xxlauraxx made it! (author)2016-05-05

This turned out so well! I adore the little boots.

She's going to love these photos forever!

Now you guys need to all dress up and do a family Star Wars photo shoot. :)

seamster made it! (author)seamster2016-05-05

Thanks Laura!

jayeff made it! (author)2016-05-05

Awesome! And so cute! :)

wold630 made it! (author)2016-05-05

OMG! She could seriously not be any cuter (or happier)!! The costume is so very well done! You're awesome! :)

About This Instructable




Bio: I got an old sewing machine when I was just a kid, and I've been hooked on making stuff ever since. My name is ... More »
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