So this Cap'n Crunch Costume was my 2007 Halloween costume and I was in my senior year of HS. I made the hat out of 2 pieces of 1" foam that were shaped like the hat and then a piece that was connected the two that ran the perimeter of the pieces. The foam was then covered with a blue fabric using hot glue.
The shirt was made from the same fabric but it was too flimsy for my liking so I backed it with a iron on stiffener. I made the shirt by hand, only basing it off of a jacket. The front end of the collar Velcrod out of the shirt and was connected in the back and then the top right seam of the shoulder unbuttoned and I was able to slide it off.
I made the epaulets out of cardboard, fabric, cotton, and upholstery edging. The buttons were buttons that you put the fabric on it and then lock the fabric onto it. The pants were just white slacks and I just wore black socks and black slip on sneakers (I wasn't going to go spend money on boots). And the mustache was a fur fabric that I had used from my previous 1960's Penguin that I attached with a sticky adhesive from an ATG gun. http://www.chops.ca/images/3m/ATG%20GUN.jpg .
If I could redo this costume I would try and find a jacket that worked and wouldn't be such a perfectionist and something that I always regret after making my costumes is taking more pictures.
Oh, and everyone loved my costume and surprisingly there was a girl dressed up as the Cap'n too, but no where near as good as Adrienne's. I would have one the costume contest but someone had to go and make an Optimus Prime costume that actually transformed, but I have to give him credit, it was pretty good.
(In the pic is my sister as Raggedy Ann (which was bought), but at least she dressed up and me).