My son wanted a Homemade Space Shuttle Halloween Costume. Space Shuttle? Don’t you mean an astronaut? –No, he corrected me, THE Space Shuttle. So here is the Enterprise—made with a diaper box and a few other boxes cut to fit, including an oatmeal box cut in half for the engine housing.
Other than that I used lots of white silver and black duct tape, painted plastic cups for the engines, and used old shiny wrapping paper for the flames. The hardest part was finding the right fonts for the logos. Of course he already had the space pajamas. Another day he wore this with an orange jacket that I made look like a space suit with labels and a tinfoil ring around his neck (where one would screw on the bubble helmet, I suppose). Stick in on with suspenders and you’re set to go!