I totally have a thing for making halloween costumes. I love how its like a unconventional materials challenge on Project Runway, and you can just velcro and glue gun your way into the final because it doesn’t have to last for more than a night. Something about this gives me the freedom to just dive in and make whatever I want like our family Yo Gabba Gabba Costumes, or last year’s Mummy costume. This year I was inspired by Studio DIY’s Fries before Guys costume and wanted to make a mini version for my fry loving toddler.
You don’t need a lot of materials for this project. I picked up spray glue, but I ended up using hot glue for everything. The fry box is made from ONE red science board poster, the fries I made from some 2″ upholstery foam and large folded felt sheets from the felt section at Michaels.
To make the box, you’ll need to do some basic measuring of your child. I decided to go about 21″ wide and 16″ tall for the front section. I sketched the basic shape, using the concave area of the front to also make the convex area of the back.
Once cut, I had my front and back pieces. I layed them over each other and trimmed any difference on the sides to that they are the same exact width. To measure the sides, I marked the height of the back and the height of the front on another piece of my cardboard, and then cut the front measurement at a slight angle, and scooped up from the front measurement to the back measurement. I did this once, and then traced the finished board onto a second board and cut out a mirror-image version of it.
Then I grabbed my trusty large-format glue gun from Ad tech. I always sing its praises, but I just love using large glue sticks – and you’ll need a lot of glue for this project.
On the frontside of my frybox, I didt want the cardboard to show through, so I cut a stray piece of my red cardboard and glued it on. To glue on the sides, I ran a bead of glue up the length and then held the side piece in place until dry. Once dry, I reinforced with a lot more glue on the inside seam I repeated this on the other side and the front. And seriously this thing is bomb proof – or toddler proof, iIm not sure which is worse. Either way, its seriously solid.
For the straps, I measured some ribbon around Leo’s shoulders and glued it in front, cris-crossed it and glued it in back. I used pieces of cardboard to reinforce the glue bonds to keep them from being stressed out.
This whole box process took about 60 minutes. And boy was Leo excited to try it on. He might have worn this box a few hours each day while I was making the fries.
For the fries, I used some 2″ foam that I had lying around. It was green so there was no chance of spray painting, but luckily I found some big 36″x 36″ felt sheets at Michaels. To cut the foam, I used a large xacto knife with a scalpel blade. I drew lines 2″ apart on both sides of the foam and then ran my blade 2 cuts deep on each side. This took forever.
But the results were well worth it. I cut the felt to width. The length wasn’t quite long enough but that doesn’t matter since you cant see the bottom of the fries. I tried a lot of trial and error on getting the edge of the fries looking great. I did find that with hot glue and synthetic felt that the glue bonds to the felt and once dry you can cut off excess felt and have a crisp seam. I ended up using this method two ways. The first was folding the felt over the top of the fry, then gluing the “wings” together, letting the glue harden and then cutting them off. Then wrapping the felt sides over and gluing to the leftover flap, and again cutting away excess once the glue had hardened.
Another slightly easier version of this, is to glue the felt all the way around the fry but leave an extra 1/2″ of excess at the top. Then cut a 2.5″x2.5″ square and hot glue all the way around the opening, making sure that the felt gets plenty of hot glue, and (carefully) pressing the felt square into the wrapped-around felt. Once hardened, all excess can be cut off and your seams look like this:
To glue in the fries, I really just used A TON of glue, and some left-over foam as spaces and reinforcements so that the fries are well supported. I was surprised how well the glue holds, but seriously this is rock solid. Both my boys ran around in it for a few hours and its in great shape.
I hope you like my DIY kid fry costume, now check out all the DIY costumes from the 49 other Michaels Makers: