This DIY Chewbacca Costume for Kids was the perfect costume for Levi when he was little. It's usually a little chilly here on Halloween and this costume keeps your little Star Wars fan warm without having to put a jacket on. Take a look below at how I made Chewbacca. You could also change up the accessories a bit and make an Ewok!

DIY Chewbacca Costume for Kids | Star Wars Halloween Costumes

DIY Costume Supply List

• Classic Zipper PJs pattern for the Costume Body
• Pattern with a hood (I used the Double Trouble)
• Faux fur (I found mine at joanns)
• Long brown zipper
• Brown & Grey felt
• Scraps of leather or faux leather
• Polyfill

Chewbacca Costume Instructions for the Body

Costume Step 1: Sew your costume's body. I added 1" to the sleeve inseam and pajama side seams to allow enough room to layer over other clothing and account for the bulky Chewbacca fur. This is a size 18 months. In larger sizes, you may want a bit more extra ease added. I skipped the feet and sleeve cuffs and did a simple hem.

I made the costume hood one size larger than usual since the Chewbacca fur is pretty bulky and my baby has a big noggin. I widened the pajama neckline to match the size of the hood and then just sewed it on with the right sides together. This was actually a very easy and quick costume to make and took me about 2 hours including cutting for the body.

You could use this as the base for tons of costumes! Faux fur is scratchy on the inside but we just layer over a thin pair of PJs and our little Chewbacca didn't mind one bit.

Chewbacca Costume Ammo Sash

Costume Step 2: Now we'll make the Chewbacca ammo sash for the costume(no clue what this is called?). Cut a piece of brown felt long enough to wrap around one shoulder and your desired width (mine is 46x4").

The Chewbacca ammo is made from gray rectangles of felt (mine are 2 x 3" and I made 4). To make the ammo 3D I boxed out each corner. Pinch the rectangle at each corner and then sew across the tip about 1/4-1/2" in from the point.

Costume Step 3: Sew 3 sides of each ammo piece to the brown sash. Stop with your needle still in the fabric, stuff with polyfill and then sew the final side.

I just did 4 pieces of ammo down the front since he will probably be sitting in a stroller. For an older kid you could make them go down the back too

Costume Step 4: Next sew a strip of leather over each piece of ammo. I did individual pieces but you could do one long strip

Costume Step 5: To keep the Chewbacca sash in place I cut a slit in one end and knotted the other end for a simple closure.

Costume Step 6: To finish the costume I hand sewed the ammo belt to the body at the shoulder to keep it from slipping off

And that's it! Now just remember...

Other Costumes for a Star Wars Halloween

We've also made a few other DIY Star Wars Halloween costumes over the years. First, you can't have Chewie without Han Solo. The Han Solo costume tutorial goes over all the ins and outs of making the DIY Solo shirt, pants, and holster. These two costumes made the perfect Star Wars Costumes for the whole family:

DIY Han Solo Costume

I made this fun Han Solo costume out of The Classic Ringer Tee for the shirt, a basic pants pattern with Navy Cotton Lycra, and some fun DIY accessories. 

DIY Princess Leia Costume

We also have a fun tutorial for Princess Leia. You can make this with this fun tutorial and the Kid's Essential Turtleneck Pattern.  

Luke Skywalker

While I don't have a tutorial for it, I also made this Luke Skywalker DIY costume for Levi a couple years ago. Like the other Star Wars costumes, this costume went together easily. The Skwyalker shirt was made from an old sheet, I easily put the costumes belt together, and added a few accessories like the lightsaber to make another fun star wars costume.

I hope you enjoyed taking a look through our Star Wars costumes today. We always love to see the costumes that our customers create so come and join our Peek-a-Boo Pattern Shop Facebook Group and make sure to share your costumes with us.