My son doesn’t have many influences in his life, so when I asked him what he wanted to be for Halloween this year, I am sure that his mind had few options. He said he wanted to be Buzz Lightyear and the first thing I thought of was “great.. armor. I can’t do armor”. The last time I tried to do armor was when I was a teenager and made my little brothers both transformers using boxes and colored paper.

So after researching the costume a little bit, I decided I wanted to do a lot of soft/lightweight materials. Stuff that he could walk around easy in, not block his vision and still be recognizable as Buzz. I looked at what was out there and quite frankly wasn’t satisfied with what I saw for a two year old.

This homemade Buzz Lightyear child costume is made from white fabric turtle neck and pants, that have colored fun foam applications. We then got some one inch upholstery pipping from Joanne’s. My wife then made “pockets” for the pipping in black t-shirt yardage and shoved the pipping into it to make the accordion style waist that Buzz has.

The buttons on his chest plate are modified emery boards and a Snapple cap button. The decals and logos were all tweaked in Photoshop and made into stickers or iron on applications.

The jet pack was a labor of love/hate and literally took me weeks to do. It?s base is made from blue camping foam that has been layered and layered with glue and caulking. Then it was spray painted to match.

The buzz gauntlets are modified plastic cups.
The boots are spray painted rain boots.

Details on how we made every aspect can be found here…