We waited untill the last minute to come up with my son's costume last year and since he already had western clothes we decided to make him a rodeo clown costume. The only thing we really had to make was the barrel.
All I did was take brown fabric and make a sleeve and put wire in the top and bottom and formed it in a circle shape. Then to keep it on him I brought some striped ribbon type stuff and made straps that look like suspenders.
We tied on a few bandannas and painted his face and we where done. Very easy to make!
Here's another writeup submitted by grandmother Luann in 2010:
My grandson at 3 1/2 years old had been to his first rodeo and really enjoyed it. Resulting in a rodeo clown costume for Halloween that year, but not just your regular rodeo clown, but complete with his own barrel. We got the easiest stuff done first. Cut off a pair of blue jeans, found a bright striped pair of pajama pants and a western shirt.
The barrel was made by making a sleeve with elastic at the top and bottom, casings sewed in the middle with wire run through it to make it stand out, and brown paint brushed on for the wood effect.
We used rainbow elastic over the shoulders to hold it up, and tied bandannas here and there for accents. Add a pair of cowboy boots, cowboy hat and clown face paint and all you need is a bull to charge and make it seem like a real life rodeo.
This is my Court Jester creation I made just recently. I'm a costume designer trying to open my own business. I made this Court Jester costume out of many different fabric; the bicycle card fabric was made from an old 80's Las Vegas button up shirt. The child wearing the costume is another one of my children. I've been doing this for about 10 years now and I'm awesome in what I do for a living. I just hope you all will love this costume as much as my family and friends do. It took hard work and a lot of sweat for this costume to be made. I honestly didn't think it would be done so quickly; but here it is ready for the whole world to see. Thank you!