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Coolest Homemade Lego Skeleton Children’s Costume

My son asked to be a Lego Skeleton mini-man figure for Halloween last year. I was quite stumped but finally came up with an idea that worked AND was comfortable for my 6 yr old to run around in!

I happened to have picked up a pair of glow-in-the-dark skeleton pajamas (Children’s Place and Gymboree are great at selling these pretty much every year for both boys and girls. Gymboree has them for adults!). The glow-in-the dark feature helps keep children visible too.

And, I finally had an idea for the Lego headpiece! *** Plan on at least assembling and painting headpiece one week (or more) before using so you have plenty of time to air this out of the spray paint smell ***

I purchased a round hat box from my local hobby store. I made sure it was large enough to cover my sons head. I removed the lid and simply plopped it over my son’s head to see if there was slightly more than enough coverage of his head and face. I also bought a smaller round mini-box for the Lego “peg” on top, foam sheets for cutting and a can of glossy white spray paint. Other supplies used were glue gun with sticks, steak knife, and a large black Sharpie permanent marker, Elmer’s Glue- all I had already.

I measured my son’s face/eyes/mouth areas and drew a template on paper ***(basically marked where his eyes/mouth areas were on a paper). I sketched over the areas- the Lego shaped eyes, skeleton nose, and mouth. I cut out the eye areas of the paper template. I placed the paper template over my hat box positioning it where my son’s face would approx be when worn. Once it was placed appropriately, I taped it on so as not to lose the positioning.

Next, I cut the foam sheets into wide strips and lined the inside of the round hatbox. ***You DON’T want to fully line it. It would be too hot & you would cover your child’s ears. You want your child comfortable & most of all safe by not obstructing his hearing.***

I cut out one round piece to cushion the top of the head (scoop or cut out some foam to conform to head. This gives a more “fitted fit” & helps keep headpiece in place). Cut another piece large enough to cushion the back of head but still allow neck breathing room. Cut two shorter strips to line the side areas above the ears ***(just enough to cushion the area above the ears). Lastly, cut one smaller strip to cushion the front forehead area making sure to stay clear of eyes.

NOTE: I didn’t glue the foam in. All foam pieces were cut, placed flush against each other, and fit nice n snug staying in place).

After I was done lining the headpiece with foam, I placed it on my son’s head to get a feel for the fit & checked the eye areas of my taped on template that I’d be cutting out. ***This is the time for any adjustments before cutting! Once, you’re comfortable with the placement of eyes & fit with foam- trace the eyes onto the hatbox, remove your paper template ***(save your paper template, you will need it to finish the nose & mouth later). Cut out the stenciled eyes with a small serrated knife (I preferred the slower serrated knife option since I could move & adjust as I went along cutting… besides, box cutters made me nervous!).

Once eyes were cut out, I got my smaller round box (don’t need the lid) & positioned it on top. Make sure you place the round box with the opening facing up. This will create your open Lego “peg” that all the mini-men figures have. Gluegun your “peg” to the top of headpiece. ***I did notice a small gap all around the outer edge of base when dried so I got regular Elmer’s glue & “caulked” all around the base of the “peg”, sealing it completely. I used my fingers to smooth it out for a nicer finished look.

Once completely dried, I taped paper on inside to cover the cut out eyes preventing spray paint from accidentally painting the inside. I took it outdoors & spray painted it glossy white. ***Taping off the inside eyes area & spraying only the outer top & sides of headpiece made me feel better about protecting my child from contact with the spray paint and/or any residual smell left. As I mentioned before, I wanted to keep this as kids friendly as possible!

Allow the headpiece to dry. While drying, go back to your paper template. Cut out the rest of the sketched skeleton nose and mouth.

After headpiece is completely dry, place your paper template over the face area lining it up with the cutout eyes. Using a pencil, lightly stencil in the nose & mouth. Remove paper template off. Get your black Sharpie permanent marker & trace the pencil outline & follow by filling it all in. Lastly, using your Sharpie- write the word LEGO on the inside of the “peg” or just find a LEGO logo out there. Print & cut it. Glue it on inside of the “peg”.

You’re done!

Our son absolutely LOVED his homemade Lego skeleton children’s costume and I quote… “Mommy, this was the best Halloween ever! People liked my costume so much they gave me extra candy!!! Next year, we have to come up with an even better costume!!!!”

Oh. Ok.

Yes. I’ve been brainstorming all summer… and I think I got it!!!!

Homemade Lego Skeleton Children's Costume

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3 thoughts on “Coolest Homemade Lego Skeleton Children’s Costume”

  1. My son, too, wants to be a Lego Skeleton. This has, by far, been the best and easiest costume to make, thanks to your input. You’re description is spot on- the step by step directions leave no guess work. Especially where safety is concerned. As a busy parent I thank you!

  2. I love this idea, and want to do it for my son’s costume this year. Could you please post a picture of the inside of the finished hat box?

    Thank you!


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