DIY Han Solo Costume

My little guy is obsessed with Star Wars so a DIY Han Solo costume was just what he needed for Halloween this year!

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He loves to dress up and has had so much fun in this costume!

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Make sure you check out yesterday’s post to learn how to make Chewbacca

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Let’s get started!

Pants
I used the Lullaby Line pants in navy cotton lycra (sweatshirt fleece would be a good choice if you want something warmer). I added a strip of 1″ red grosgrain ribbon down each side before finishing the waist and hem. If you already own navy pants you could just baste the ribbon in place.

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Shirt

For the shirt I used the Classic Ringer Tee pattern as the starting point and sewed it up in cream cotton lycra. I brought the neckline in a bit and cut the front and back the same to give it a bit of a faux collar. Since this is just a costume I slit right down the center a couple inches and just left the neckline edges raw. I lengthened the sleeves a couple inches and did a normal hem instead of cuffs

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Vest

I also used the Classic Ringer Tee as the starting point for the vest. I made mine from twill so I had to line it but if I did it again I would use felt or fleece and skip finishing all of the edges. His vest has 4 pockets on front. I added flaps to the bottom 2 pockets

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Holster

The holster is the  key piece to Han Solo’s costume. I made mine from scraps from a thrifted leather coat but faux leather would also work. It’s a simple velcro closure with a gray felt “buckle” topstitched on. I laid his toy gun right on top of my leather and traced around it leaving some extra wiggle room.

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The holster portion goes on the right side of the body

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To connect the holster to the belt I used 2 stripes of leather and some d-rings

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Boots

Borrowed from big sister :)

Happy Sewing!

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Amy is the founder and owner of Peek-a-Boo Pattern shop. She is a wife and mother to 3 children. Amy loves to sew, read and spend time outdoors.

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