Coolest Airplane Costume

For this Bi Plane Costume I started out using four cardboard boxes and four rolls of Duct tape my favorite…

The first box is the largest of them. I cut a hole in it to place over the pilot’s head to make sure he can get into it from the bottom and that he can walk in it. Then, once complete, I always look at it as if to semi scale a person wearing it. I try to see it before I build it.

My 9 yr old Josh is the pilot. He is getting bigger and you see him in the transformer costume and in the tank costume I have built.

Yes you have to be a bit of a junk collector and have a piece here and a piece there. You just have to envision what it can be used for. Recycling is a fantastic way to make these creations.

I wrap every inch of the cardboard plane in duct tape when I have it complete. I use Krylon primer spray paint. It helps adhere the top coat this year was krylon red and satin black for the engine cowl.

The reason for all the duct tape is that cardboard is funny – a little bit of moisture and it’s done (warps, bends, swells). The duct tape makes it possible to also fill in gaps and spaces. It’s OK if it’s folded over and over it and makes the plane tighter and more solid.

I also used a plastic cup and cardboard tubes for the upper wing support.

This time on my plane I took a remote control truck they had that was smashed but still worked and took it apart. I wanted to use it use the rear axle to put on the engine cowl so that the propeller will spin when he pulls the trigger. He loved it!

Another product I used is glue and epoxy to hold the little rear axle on the cardboard and I used a CD and the rim of the toy truck tire to conceal the motor behind it and a spray paint can as the piece on middle of blade.

A pair of suspenders are used so he doesn’t have to carry it and it rides on his shoulders… And he is free to walk about freely like he is flying…

It started out as the Red Baron, but I decided not to put Iron cross’s on it so I used our neighborhood group symbol…

Thanks to Signs by Raymond in Pt. Pleasant for the decals that are applied.

I also try to use Krylon clear coat to protect it even more. Don’t go crazy, it has a tendency to shrink both tape and paint so go lightly and many coats, but not truly needed…

If you have any questions you can post them here and I’ll comment back.

Airplane Costume

Airplane Costume

Coolest Homemade Costume Contest 2023

11 thoughts on “Coolest Airplane Costume”

  1. That is a very cute airplane costume. I was wanting to know how you attached the wings and suspenders? Also how is the top of the airplane connected? Also, how did you attach the rest of the boxes together?

  2. Hi I was wondering how you connected the back wings on. I’m making a airplane but don’t know how to put the back on. and what did you use for the front of the plane.

  3. My friend has asked me to help her make a plane costume for her son who wants to be nothing else. This is great but yes, I need specifics and fast – I haven’t been given much time. How did you attach everything and what size of boxes?? The front round part is cut from a box, too?

  4. Bob,

    Can you give me the dimensions of the middle, back part, wings, etc. I am a mom that is not very good with this stuff, but my 4 year old SO badly wants to be a plane this Halloween. I could sure use your help. Thank you, JoAnna

  5. We built this biplane costume for our son this Halloween with a few mods:
    – dropped the gun (as ordered by granny)
    – made the propeller rotate by cutting up a car fan (that plugs into the ciggie lighter) and wiring it into a 9V battery.
    – put a collection of truck running lights on top of the upper wing connected to a 6V battery.

    The costume was a hit! Thanks for the great idea, it gave me and my family hours of fun (and torment) making it and the smile he had when he put in on for the first time was absolutely priceless.

  6. Took the idea and ran with it, my grandson wanted a P-40, I eliminated the top wing, changed the radial engine to inline and no power propeller (he’s only 5) plan to use light sticks for wing tip lights.

  7. i am in the middle of making this for my son. first i found 2 boxes, 1 slightly smaller than the back and used old Cd’s to attache them from the inside, then taped the Cd’s down. next i cut a hole in the center of the big box and made the wings with cardboard. i attached them with an old plastic table that has the tubes.i cut holes in the box top and bottom where the tubes would fit snug.then made the back wings using cardboard and will use Halloween flashing lights for decorations as well as stickers and will try to make the front round piece and propeller using a pull string. haven’t gotten that far yet but will post more later.


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