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Coolest Homemade Polar Express and Conductor Costume

My son is OBSESSED with The Polar Express. So when he said he wanted to be the Polar Express for Halloween, I did what any mother would do for her child. I made him a Homemade Polar Express and Conductor Costume! And to top it off, we used a blue suit and old TWA pilot’s hat to make him the conductor.

I’m missing the spectacles and tie, but I figured I made my point with the mustache. I printed out a conductor badge, printed on it the words “Polar Express” and tacked it to his pilot’s hat. He also carried a ticket puncher with him.

The train was made out of a cardboard diaper box. I added construction paper for the add-on pieces (the top of the engine, the smokestack, the front where the light is, the bottom front (the grill? I don’t know the names of the train parts!) and rounded sides. The rounded sides were attached by using a paper cutter to slice through the diaper box and slide cardboard construction paper into the groves and fold and tape them into the inside. I used paper plates for the wheels, attached with nuts and bolts.

Everything was spray-painted glossy black with metallic champagne trim and stick-on letters were added that I found at Michael’s. I used the hole in the diaper box that is the “handle” to place a flashlight, so he would have a working train light to lead the way in the dark. I attached banding from the fabric store as straps to hold the train up on him.

Polar Express Costume

Polar Express Costume

Polar Express Costume

Polar Express Costume

Polar Express Costume



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5 thoughts on “Coolest Homemade Polar Express and Conductor Costume”

  1. This costume is amazing!!! I’m so excited!!! My 3yr old is obsessed with Thomas so I’m going to use your idea and make it a Thomas train. I love the idea of it being simple enough, for a not so crafty mom like myself to make, but yet looks amazing!! Thanks so much for sharing!!!

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  2. My son and your son could be best friends! He is 3, and the only thing he talks about is trains, he eats, lives and breathes trains. Everyday he tells me he wants to be a Big Black Engine for Halloween, I have been trying to talk him into something else, now I dont have to. He is going to be soooooo excited! Thank you for your creativity and sharing!

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  3. Thank you so much for the pictures during construction! I’m huge on visual learning! On my way to get the supplies tonight! I did a Thomas 2 dimension a few years ago for my now 5 year old who has to be the Polar Express. I’m so excited and I know he’ll love it! Great Work and imagination!

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  4. We have a dress up theme for Christmas at work this year. As I work Night fill I had to come up with something other than the usual Santa, Elf, Christmas bauble, Snowman, Christmas Tree, reindeer and all other things that resemble the Christmas theme. Also something to work in all night. I remember seeing your delightful, absolutely amazing Polar Express costume and thought how fantastic! Of course I won’t be wearing the train all night as it would be difficult to work in the surroundings whilst filling stock and so forth. I will however wear it for most of the night so that our staff, and patrons will see it as our store is open until midnight ever night now up til the day before Christmas eve. Thank you for sharing your brilliance!

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