Astronaut Costume




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I love space. So I decided to make a space suit** for halloween. It was super fun to make, and relatively inexpensive.

I was able to make it out of things I had lying around from old projects. I imagine that if any maker-type wants to put this together, that already has a stock of supplies will only have to spend 20 or so dollars to complete this project.



Step 1: Gather Materials

For Helmet:

  • Wood Glue
  • Water
  • Really round balloon (available at party stores)
  • Phonebook
  • Wood Filler
  • LEDs
  • 9V Battery
  • 9V Battery Clip
  • PCB
  • wire
  • Hot Glue Sticks
  • White Acrylic Paint
  • Silver Spray Paint

For Space Suit:

  • Painter Suit
  • White Satin
  • Silver Lame
  • Interfacing
  • Felt
  • Hot Glue Sticks
  • Thread


  • Stir Stick
  • Scissors
  • Gloves
  • Razor Blade
  • Sand Paper (80 Grit and 150 Grit)
  • Soldering Iron
  • Wire Snips
  • Wire Strippers
  • Paint Brush
  • Bowl
  • Sewing Machine
  • Serger
  • Glue Gun

The hardest thing to find for this project was a phonebook.

Step 2: Blow Up Balloon, Mix Glue, and Cut Strips.

If you are using wood glue, you can use a 1:1 ration of water to glue, and coat your paper strips with them before you apply them to the balloon.

Step 3: Paper Mache!

There are lots of really good Instructables on how to paper mache, after a little research I believed I was ready to begin. I dipped each strip into my gluey water and then applied it to the balloon. I think I ended up applying six layers of paper, and it took....... a long time.

When I was done applying the strips, I made a slightly thicker glue/water solution and brushed it over the entire surface of the sphere.

Then, walk away. This guy took two days to dry.

Step 4:

Using a razorblade, I pierced the balloon. I cut a hole big enough for my head, and then separated the balloon from the paper.i

Step 5: Fill, Sand, and Paint!

After the helmet had been fit, I had to remove some of the large wrinkles from the sphere - so I used some wood filler! I sanded the entire sphere with 80 grit sandpaper so that the wood-filler would bond to the sphere.

Again, wearing gloves, I squeezed the wood filler from the tube and smoothed it into the cracks. It took about two hours to dry.

I then re-sanded the entire helmet with 150 grit sand paper.

Step 6: Painting and Cutting.

I painted the outside of the helmet with white acrylic paint. It took about 30 minutes to dry.

I then traced out a  basic shape around the sphere that would be the helmet's opening. Using the razor blade, I cut the opening out.

Using some bailing wire, and some masking tape, I reinforced the cut edge of the helmet, so that it wouldn't slump on my head. I then sprayed the inside of the sphere with silver spray paint.

Step 7: Add LEDs to the Helmet.

I plugged in the hot glue gun, and the soldering iron.

I soldered 4 LEDs to eachother, in preparation to make parralel series that could be powered by a 9V battery. Then, I glued down the LED series, and ran wires all through the helmet to one PCB.

I plugged in a 9V battery, and it worked! Onto the suit!

Step 8: The Suit!

This part is pretty fun. It's great because I was able to imagine whatever I wanted to put on to the suit. I based it of a really big painters suit that was about 8 bucks from the hardware store.

I made up some elbow and knee patches out of silver lame and interfacing, making rippled waves with the sewing machine, then cleaning up the edges with a serger. I had to open the legs and the arms of the suit to sew down the patches.

Step 9: Go to Space.

I realized that the more bulky this suit looked, and the more panels I added the more authentic it seemed. I want to grow the costume to  be appropriate for other festivals and events where I could sport an astronaut costume.

I paired the suit with my super busted snowboard boots, and they looked great. The paper suits are a bit flimsy, but a great base for this costume. 

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    21 Discussions


    1 year ago

    I made his helmet based on yours!


    2 years ago

    tyvm for the helmet guide, should be very useful. I've already bought white overalls (boiler suit) and had been planning to use an outdoor lighting post topper, but too expensive and time consuming, especially when shipping factored in. All the 'detail' will done with EL wire.


    2 years ago

    I am going to use this method but instead im going to make a Koro Sensei head for a cosplay!!! Thanks so much!!!


    4 years ago on Introduction

    I'm curious about the bailing wire. Was the helmet not stiff enough to hold its shape when you finished? Did making the cut out compromise the integrity of the shape? Would love a little more information about why you thought it was necessary.

    2 replies

    It did bow a little, but the wire helped. If I had more layers of paper, it may not have bowed.

    If I was to do it all again, I would just fiberglass the whole helmet.


    5 years ago

    U could vacuum form a shield for the helmet


    6 years ago on Step 9

    Thanks it was great idea and easy to make costume. I made a small changes and it was areal blast at the party

    2 replies

    5 years ago on Step 9

    i want to wear this in a landscape made of cheese :D yayyyy!!!


    6 years ago on Introduction

    I made a similar suit myself this year, but I decorated the suit to match Felix Baumgartner's suit.. =) I was going to put a slight twist to it though.. Going to,., because I found out my job wouldn't allow it this year... but anyhow.. I was going to put a nice big brown stain on the backside... =) So I got a suit but no where to wear it!


    6 years ago on Step 9

    Great space suit!

    I made a very similar one in 1973. I blew up a balloon and covered it with plaster, then pulled the balloon out and used the plaster mold to lay up a fiberglass helmet. I cut a big hole in it and bolted in a motorcycle bubble-style face plate, filled the gaps with body putty, sanded and painted it. They didn't have Tyvek painter's suits back then, but I found a silly exercise suit made of mylar (you're supposed to lose weight by excessive sweating) that worked pretty well. I wore welder's gloves and some old rain boots with it.

    When I wore it in public, I would take the helmet off and say "One small step for a woman -- one giant step for womankind!"


    6 years ago on Introduction

    Out of this world!!! (Sorry, just had to do it....) So creative and fun and very well done, plus bering inexpensive, relatively easy, AND customizable!

    1 reply