DIY Homemade R2D2 Star Wars Halloween Costume

  This costume took a little longer than expected because of cutting all the small shapes out. I spent about $6 on fabric and $4 on foam. I also used hot glue, cardboard and paper mache. I made this a lot like I did the Minion costume. You can find this costume and all my others on

Step 1: Paper Mache

 I used an exercise ball to use for the form of the head. I covered half of it with about 4-5 layers and let it dry overnight. You could also use a large punch balloon. The size I made will fit an adult up to about 200 pounds. So if you're making it for a child I would use the balloon instead. I covered about half of it in paper mache. Alternating colors to make sure I have compete layers on it.

Step 2: Body

After drying remove from ball or pop balloon. Trim around the bottom, make sure it's fairly even. Then I took cardboard and rolled it up to crease it so it will keep a circle form. Then I hot glued the head form to the cardboard. The cardboard on the outside. You can glue additional piece of cardboard to help shape the form a little better if needed. Then I cut one large opening to see through and a comfortable spot on both side for your arms to come through.

Step 3: Sewing

I used exactly 1 yard of fleece white fabric for this at $5.59 a yard. Cut into 4 equal parts, and cut to a point on one end. Sew all four together all the way through the points to form a dome shape. This should slide right on over the form. I trimmed the bottom of the cardboard a little so I could glue the fabric on the inside of the bottom. Then I just cut different geometrical shapes out, some using my Cricut Cutter but mostly just by hand. There are a few "Staples" of R2D2, I'm no expert so I made sure I hade the three long lines in the front, the 1 big eye on top, the small circle next to the eye and the red button. I used foam for all the details. For the eye I used a see through fabric and glued in to the blue foam and then glued the entire thing to the body. I did the trim around top, all the way around but there are no other details on the back. Hope you enjoy!!



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    2 Discussions


    Reply 5 years ago on Introduction

    Thanks. Its a good size, Ill probably make a minion like this too. Best part is with a little food release I can reuse it. Thanks again!!